GM Holden is recalling some Isuzu Thailand-built RA Rodeo light truck variants, model years 2003 to 2005, with petrol engines and original equipment fitted tubs (load trays).

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The recall will involve about 22,000 vehicles in Australia and New Zealand but does not include cab-chassis models or those with diesel engines.


The recall has been issued following reports that owners filling their vehicles had experienced a brief event known as fuel flash, caused by a mixture of air and fuel vapour coming into contact with static electricity built up during the filling process. This event occurs outside the fuel filler with minimal further risk to the vehicle. Nineteen incidents involving RA Rodeo have been reported with minor burns in some cases.


GM Holden executive director engineering, Tony Hyde, said the issue occurred because the fuel filler nozzle may be pushed towards the vehicle body during the filling process, where the hose clamp connecting the pipe into the tank discharges static electricity.


Hyde said GM Holden and Isuzu had identified a root cause and instructed its dealerships on a rework which earthed the clamp through the vehicle body, eliminating any charge build-up at the clamp. As a related matter, vehicles modified after sale by removing the original equipment tub will have their fuel filler replaced in case the original fuel filler design had been compromised.

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GM Holden and Isuzu have been investigating the issue since late last year after receiving two incident reports in eight months. The problem was identified on Rodeos on which the tubs had been removed and aftermarket trays installed, potentially adjusting or exposing the fuel filler pipe. Further investigations identified an issue on petrol Rodeos with tubs which had not been modified.


Hyde said Rodeos with diesel engines were not affected because diesel was not combustible at normal temperatures, and cab chassis Rodeos were not affected because they had a different fuel filler system.