1996 Chevrolet Suburban Electrical Problems

THE BATTERY CABLES LEAK ACID, . WHEN THE BATTERY BECOMES CORRODED, THERE IS NO POWER TO THE VEHICLE. THE DEALER HAS TOLD ME THAT THE BATTERY CABLES ARE BAD, WHICH WE HAVE REPLACED, AND THE PROBLEM CONTINUES. WE HAVE HAD THE BATTERIES (REPLACED MORE THAN ONE) CHECKED, AND THEY ARE FINE. WE HAVE HAD THE POSTS REPLACED, AND THE PROBLEM GETS WORSE. THE LATEST, (IM STRANDED RIGHT NOW) SEEMS TO BE THE WORST YET. AT FIRST WHEN THIS STARTED HAPPENING, IT WAS A COUPLE OF MONTHS APART, NOW ITS EVERY WEEK. ALSO WHEN IT STARTED THE CABLES WHERE REALLY CORRODED BEFORE THE ENGINE QUIT. NOW THEY CAN BE WIPED OFF WITH A DRY TOWEL. ALSO, THE A/C HAS STOPPED WORKING DUE TO CRACKS IN HOSES. (FROM THE ACID) BEING AS I LIVE IN TEXAS, EVEN IF THE TRUCK IS RUNNING I CANT DRIVE IT IN THE SUMMER, EVEN IF WE FIX THE HOSES IT HAPPENS AGAIN. WHEN I HAD THE VEHICLE TOWED TO THE DEALER THE LAST TIME, THEY TOLD ME THE BATTERY WAS FINE, BUT I NEEDED TO SPEND 400.00 TO HAVE THE CABLES REPLACED AGAIN. HOW IS THIS PROBLEM REALLY CORRECTED. TALKING TO OTHER PEOPLE WHO HAD SUBURBANS I HAVE FOUND THAT A NUMBER OF THEM HAVE HAD VEHICLE FIRES DUE TO THE ACID PROBLEM!!! HAVING CHILDREN IN THE CAR, IM TERRIFIED TO DRIVE MY TRUCK. (WHEN IT EVEN STARTS) I CANNOT SELL IT TO SOMEONE ELSE AND PUT THEM IN DANGER. THE FUEL PUMP HAS FAILED. WE WERE TOLD THAT WE HAVE TO KEEP A 1/4 TANK OF GAS IN THE TRUCK. WELL IT IS GOING OUT AGAIN AND I KEEP IT FULL! ALSO, SOMETHING TO DO W/ THE ABS BOOSTER BEING BAD. WELL MY BRAKES ARE FAILING AGAIN. (LESS THAN A YEAR LATER) THE PADS ARE FINE. THE ACID LEAKING HAS CAUSED DAMAGE TO OUR DRIVEWAYS, NOT TO MENTION THE KIDS AND ANIMALS IN THE NEIGHBORHOOD GETTING INTO THE ACID ON THE GROUND. PLEASE SEND ME ANY INFO THAT MIGHT HELP ME. IM AM GOING TO CONTACT THE DEALER AND TALK TO THEM AGAIN ABOUT THE INFORMATION THE I HAVE FOUND, RE: IM NOT THE ONLY ONE THIS IS HAPPENING TO. *NM

NHTSA ID

10148079

Incident

Jan 19, 2006

DRIVING FROM WORK-SNOWY/ICY CONDITIONS. SMELLED A STRANGE ODOR IN VEHICLE GOING FROM I-270S TO I-370W ~ 1/4 MILE FROM RAMP. TRAFFIC MODERATE. TRAVELING 45 MPH I TAPPED BRAKES, THEY WENT ALL WAY TO FLOOR. TURNED OFF ELECTRICAL EQUIPMENT. USED ENGINE BRAKING SELECTING 3-2-1 TO SLOW VEHICLE. VEHICLE SLOWED, APPLIED EMERGENCY BRAKE - DROVE TO BRAKE DOWN LANE. VEHICLE STOPPED-WHITE SMOKE COMING AROUND EDGES OF HOOD. LOWER PORTION OF WINDSHIELD HAD COUPLE OF HEAT DISCOLORATION MARKS ABOUT 1/4 SIZE OF A PENNY IN THE MIDDLE LOWER PORTION. AIR BAG LIGHT CAME ON. DASH DID NOT FEEL HOT, NOR THE INSTRUMENT PANEL - NO SMOKE INSIDE VEHICLE. HOOD WOULD NOT OPEN BY HOOD RELEASE. POWER WINDOWS WORKED. EGRESSED VEHICLE AND DRIVER SDIE AIR BAG INFLATED. CALLED 911 AWAITED FIRE/POLCIE DEPT. OPENED DRIVER'S AND PASSENGER DOORS. FLAMES COMING FROM STEERING COLUMN WHERE IT ENTERS FIRE WALL. FLAMES UNDERNEATH VEHICLE FROM ENGINE NEAR SKID PLATE/TRANSFER CASE. USED SMALL FIRE EXTINGUISHER ON FLAMES IN CABIN AND UNDER VEHICLE TO NO AVAIL. FRONT DRIVER'S SIDE FROM CENTER CONSOLE TO DRIVER'S SIDE DOOR MELTED AWAY AT ABOUT 45 DEG ANGLE FROM TOP TO BOTTOM OF CONSOLE. INSIDE ENGINE THE THYDRAULIC DRIVE UNIT AND BARKE MASTER CYCLINDER HAD MELTED. SIGNIFICANT BURN DAMAGE FROM FIRE IN ENGINE. VEHICLE-TOTAL LOSS. VERY FORTUNATE TO RECOGNIZE BAD SMELL, ID BRAKE MALFUNCTION, USE ENGINE BRAKING TO CONTROL VEHICLE; USE EMERGENCY BRAKING TO STOP - MODERATE TRAFFIC. MINIMIZED POTENTIAL HAZARD TO SINGLE VEHICLE-NO INJURIES OR FATALITIES. *JB

NHTSA ID

10107606

Incident

Jan 13, 2005

Mileage

174,000 mi

FAN SWITCH LOCATED ON THE DASHBOARD THAT CONTROLLED THE AIR VENTILATION MELTED THE WIRING HARNESS. DEALERSHIP REPLACED THE SWITCH AND THE WIRING HARNESS TWICE. DEALERSHIP INDICATED THAT THIS WAS A HIGH DEMAND PART. *AK

NHTSA ID

10074113

Incident

Jun 12, 2002

Mileage

50,000 mi

1996 CHEVROLET SUBURBAN, SIDE MIRROR REMOTE CONTROL IN DRIVERS DOOR PANEL CAUGHT ON FIRE. I TORE OUT THE PANEL AND CUT THE WIRES TO REMOVE IT BEFORE THE TRUCK CAUGHT COMPLETELY ON FIRE. *JB

NHTSA ID

10062711

Incident

Mar 20, 2004

Mileage

125,567 mi

CONSUMER STATED THAT WHILE DRIVING VEHICLE CUT OFF. CONSUMER TOOK VEHICLE TO A CHEVROLET DEALER/MECHANIC, AND EACH TIME WAS TOLD THAT VEHICLE NEEDED NEW BATTERY CABLES. THE BATTERY CABLES WERE REPLACED TWICE, BUT VEHICLE KEPT DOING THE SAME THING. *AK

NHTSA ID

10047932

Incident

Nov 13, 2003

PROBLEM: ENGINE SHUTS OFF AT ANY SPEED. WILL RESTART. AFTER NUMEROUS VISITS TO DEALER BETWEEN APRIL 99 AND JAN 2000 AND FUEL PUMP REPLACED 3 TIMES AND PROBLEM CONTINUED. PROBLEM WOULD OCCUR ON INTERSTATE AT HIGH SPEED, OR IN THE MIDDLE OF AN INTERSECTION DURING ACCELERATION, OR WHILE IDLING. LOSS OF CONTROL A PROBLEM ON WINDING ROADS OR WHILE ENGAGING AN INTERSECTION. DEALER FINALLY REPLACED ECM (COMPUTER) IN JAN/FEB 2000 AFTER A LETTER TO DEALERSHIP PROBLEM CORRECTED. MFG. EXTENDED WARRANTY TO 120,000 MI. ENGINE SHUT OFF AND WOULD NOT RESTART IN MARCH 2002 REAR TRANSFER PUMP REPLACED. IN NOV. 2002, ENGINE HAS BEGUN TO SHUT OFF AGAIN (AT LEAST 5 TIMES) SINCE 11/20. I ANTICIPATE A LARGE BILL FROM DEALER TO CORRECT A RECURRING PROBLEM. WILL TAKE TO DEALER THIS WEEK (12/2/2002). DT

NHTSA ID

770297

Incident

Nov 30, 2002

VEHICLE CAUGHT ON FIRE ON DRIVER'S SIDE DOOR DUE TO AN ELECTRICAL SHORT IN WIRING. VEHICLE WAS TOTALED. MANUFACTURER HAS BEEN NOTIFIED. PLEASE PROVIDE ADDITIONAL INFORMATION.*AK

NHTSA ID

892095

Incident

May 26, 2001

ORIGINAL BATTERY LEAKED ACID, REPLACEMENT BATTERY LEAKED AS WELL. ACID CORRODED AIRBAG SENSOR AND WIRING, CAUSING AIRBAG SYSTEM FAILURE. *AK

NHTSA ID

740375

Incident

Jan 1, 2001

CONSUMER WAS TRAVELING ABOUT 60 MPH ON MAJOR HIGHWAY AND VEHICLE JUST SHUT OFF WITHOUT PRIOR NOTICE WHILE PULLING A TRAILER. THERE WERE NO INJURIES. *AK

NHTSA ID

877447

Incident

Oct 27, 2000

TRANSMISSION SHAFT HOUSING CRACKED IN HALF BECAUSE THE CASTING WAS TOO THIN. *SLC

NHTSA ID

556154

Incident

Sep 1, 2000

CONSUMER HAS REPLACED BRAKES 5 TIMES; 2 SETS OF ROTORS & REPLACED DRUMS 1 TIME. DEALER SAID THAT VEHICLE WAS HEAVY, AND IT WAS GOING TO GO THROUGH BRAKES. THEY HAVE TRIED TO PUT DIFFERENT PADS ON, BUT NOTHING WORKED.*AK PINION SEAL WAS LEAKING AND THE VEHICLE MAKES NOISE WHILE TURNING. WIPERS MALFUNCTION DUE TO WIPER MODULE FAILURE. THERE IS A WHINE IN THE FRONT PART OF THE ENGINE DUE TO ALTERNATOR FAILURE. *YH

NHTSA ID

872388

Incident

Dec 1, 1998

CHEVROLET, SUBURBAN 1996, LS 1500, 4 X 4 I HAVE ONLY OWNED THIS CAR 2YRS, I HAD TO PUT ON 5 SETS OF BRAKES, 2 SETS OF ROTORS, DRUMS, STEER KNUCKLES, ALTERNATOR, WINDSHIELD WIPER MOTOR, BATTERY, DIFFERENTIAL/AXLES REPLACED AND AIR CONDITION UNIT HAS FOWL SMELL AND THE BACK PASSAGER DOOR STICKS AND WON'T OPEN MOST OF THE TIME. I BOUGHT IT AS A LEASE RETURN WITH 34,900 MILES ON IT. PLEASE HELP ME FIND OUT WHY THIS CAR IS STILL BEING SOLD. I ONLY DRIVE THIS SUBURBAN IN EMERGENCY.*AK

NHTSA ID

733543

Incident

Sep 26, 2000

BATTERY LEAKS AND SUBSEQUENT POSITIVE CONNECTOR/CABLES ROTTENING FROM ACID PREVENT CURRENT FLOW TO THE STARTER AND TO THE COMPUTER - SO THAT THE ENGINE WILL NOT START. IT IS NECESSARY TO LOOSEN THE BATTERY CABLES, AND CLEAN SOAK THEM IN A MIXTURE OF SODA AND WATER, THEN REHOOK! MY WIFE CAN NO LONGER USE THE CAR, BECAUSE SHE IS UNABLE MAKE REPAIRS OF THIS NATURE, IN THE VERY GOOD LIKELIHOOD THAT THE FAILURE TO CRANK WILL OCCUR WHEN SHE IS DRIVING. I HAVE PREVIOUSLY REPORTED THIS, BUT DID NOT REPORT THAT I HAVE JUST DISCOVERED THAT BATTERY ACID LEAKS HAVE CAUSED SEVERE RUSTING OF THE RIGHT FRONT BRAKE TUBING DIRECTLY UNDER THE BATTERY CONNECTIONS. THIS PRESENTS A POTENTIALLY SERIOUS SAFETY MATTER. FYI, THE CAR NOW HAS HAD 3 DELCO 78 SERIES BATTERY IN IT - FIRST TWO REPLACED BECAUSE OF LEAKING!! , AND NOW THE NEW 3RD ONE IS LEAKING. WILLIAM J FISHER. *AK

NHTSA ID

732641

THE INITIAL SYMPTOM HAS BEEN UPON STARTING THE ENGINE THE CLOCK RESETS TO 1:00 AND THE AIR CONDITIONER LIGHTS GLOW ON AND OFF(BUT THE A/C SWITCH IS OFF). THE NEXT SYMTOM IS WHILE DRIVING THE ENGINE WILL JUST DIE UNEXPECTEDLY. THE SUBURBAN HAS BEEN TAKEN TO SEVERAL DEALERS. THE BATTERY HAS BEEN REPLACED 4 TIMES SINCE THE VEHICLE WAS PURCHASED IN MID-1996. THE BATTERY HAS LEAKED SO BADLY THAT PARTS UNDER THE AREA WHERE THE BATTERY SITS HAD TO BE REPLACED. BESIDES WHAT SEEMS TO BE ELECTRICAL PROBLEMS, THE BRAKES IN THE FRONT HAVE ALREADY BEEN REPLACED 4 TIMES. THIS LAST TIME THE ROTERS WERE REPLACED BECAUSE THE DEALER SAID THEY WERE OUT OF MFG. SPECIFICATIONS. BRAKES AND BATTERY REPAIR ARE NOT UNDER EXTENDED WARRANTY. EACH TRIP TO THE DEALER IS MORE $500.00. THE POTENTIAL FOR A LIFE ENDING ACCIDENT IS SO GREAT WHEN THESE SYSTEMS FAIL ON A VEHICLE. WHY AREN'T THESE VEHICLES BUILT WITH BETTER RELIABILITY? THE TRUCK WAS PICKED UP FROM THE DEALER ON 9/11/2000. THE ELECTRICAL PROBLEMS ARE STILL NOT FIXED! (DESCRIPTION OF VEHICLE: CHEVROLET SUBURBAN, V8 VORTEC 454, 4X4, 3/4 TON). *AK

NHTSA ID

731013

Incident

Sep 3, 2000

POST ON BATTERY BROKE OFF. BATTERY ACID HAD LEAKED FROM THE BREAK. TRANSMISSION FAILED, FLUID LEVEL HAD BEEN CHECK APPROXIMATELY 10 DAYS PRIOR TO FAILURE. FLUID LEVEL WAS FINE.

NHTSA ID

729339

Incident

Aug 25, 2000

DELCO BATTERY WAS CRACKED CAUSING ACID TO LEAK DOWN THE WIRING TO THE FRAME. NLM

NHTSA ID

553891

DEALER REFUSED TO WARRANT THE CABLE, ALTHOUGH THE EXTENDED WARRANTY CLEARLY INDICATES THAT IT WAS COVERED.*AK

NHTSA ID

725215

THE VEHICLE MAKES A HUMMING SOUND AND INCREASES AS IT ACCELERATES DUE TO THE TRANSMISSION OIL PUMP AND THE TORQUE CONVERTER FAILURE. YH

NHTSA ID

552886

Incident

Jul 1, 1998

ACID LEAKAGES FROM DELCO BATTERY POST. THIS WAS THE THIRD TIME THAT THIS PROBLEM OCCURRED. FEEL FREE TO PROVIDE FURTHER DETAILS. *AK

NHTSA ID

864567

Incident

Jun 27, 2000

NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK

NHTSA ID

724666

Incident

Mar 12, 1997

THE ORIGINAL BATTERY LEAKED AND CAUSED A POWER OUTAGE,CAUSING THE POSITIVE CABLES TO EVENTUALLY START CORRODING INTERNALLY.THE DEALER REPLACED THE DEFECTIVE BATTERY UNDER WARRANTY.SEVERAL MONTHS LATER THE REPLACED BATTERY CAUSED THE SAME PROBLEM,BUT THIS TIME IT INTERNALLY CORRODE THE POSITIVE CABLES.I WENT TO THE DEALERSHIP AND EXPLAINED TO THEM THAT THE BATTERY LEAKED AGAIN AND CORRODED THE POSITIVE CABLES.THEY REFUSED TO REPLACE THE BATTERY.SO I HAD TO BUY A NEW BATTERY AND BOUGHT A NEW PAIR OF POSITIVE CABLES AND INSTALLED THEM MYSELF.I FILED A COMPLAINT WITH GM AND THEY DID NOT DO ANYTHING ABOUT IT.I CONTACTED AC DELCO TO TELL THEM THAT I FELT THAT THEY HAD A BATTERY PROBLEM AND THEY NEVER CONTACTED ME BACK.

NHTSA ID

724569

FIRST TIME AT 30,000 MILES, SYMPTOMS APPEARED TO BE DEFECTIVE STARTER OR STARTED SOLENOID- FOUND THAT THE BATTERY WAS LEAKING AT THE POSITIVE TERMINAL AND CORRODED/RUINED CABLE CONNECTING TO BATTERY. DEALER IN NORTH CAROLINA [PARKS CHEVROLET, CHARLOTTE REPLACE BATTERY AND CABLES, FREE]. SECOND TIME, AT 50,000 MILES, I CHECKED BATTERY AND FOUND LEAKING AGAIN - SOAKED CABLE CONNECTIONS IN BAKING SODA WATER SOLUTION AND RE-INSTALLED WITH NEW BOLT. SINCE THAT TIME, I HAVE CLEANED THE CABLE CONNECTION AT BATTERY POSITIVE POST WITH SODA/WATER SOLUTION AT APPROXIMNATELY 10,000 MILE INTERVALS. FROM TALKING TO OTHER OWNERS, IT APPEARS THAT THE BATTERIES ARE THE PROBLEM - LEAKING AT THE POSITIVE BOLT/TERMINAL CONNECTION. AS A FORMER MECHANIC AND FACTORY SERVICE REP, I HAVE BEEN ABLE TO AVOID A SERIOUS THREAT TO SAFETY BY FREQUENT INSPECTION AND MAINTENANCE, BUT THIS IS REALLY A DANGEROUS SITUATION AND MAY HAVE FRIGHTENING RESULTS UNLESS SOME ACTION IS TAKEN TO CORRECT

NHTSA ID

724477

NO SUMMARY LISTED FOR ABOV EVEHICLE. *AK

NHTSA ID

724405

Incident

Nov 1, 1999

IN FEBRUARY MY CAR DIED WHILE LEAVING A PARKING LOT. I TURNED OUT TO BE ACID CORROSION ON THE BATTERY. I HAVE ALREADY HAD TO HAVE MY POSITIVE BATTERY CABLE REPLACED UNDER EXTENDED WARRANTY DUE TO ACID CORROSION. EVEN AFTER CLEANING THE ACID OFF I AM STILL HAVING PROBLEMS AND WILL HAVE TO REPLACE THE BATTERY EVEN THOUGH IT SAYS IT IS STILL GOOD. I KNOW OF ANOTHER SUBURBAN (95) ALSO HAVING THE SAME PROBLEM.

NHTSA ID

724381

Incident

Feb 28, 2000

THE BATTERY LEAKED/SPRAYED ACID ONTO THE ENGINE AND RIGHT FRONT SIDE COMPONENTS OF THE SUBURBAN. THE AIR BAG SENSOR HAD TO BE REPLACED, BUT THE REST OF THE COMPONENTS WERE JUST CLEANED OFF (THIS INCLUDED BRAKE HYDRAULIC CABLES AND LINES, BRAKES, AIR CONDITIONING HOSES, RADIATOR, ETC.). THE DEALER/MANUFACTURER SAID THEY DON'T COVER THE BATTERY BECAUSE IT IS NOT MADE BY THEM ALTHOUGHT I THINK THE COMPANY IS OWNED BY THEM. WE HAD TO BUY A NEW BATTERY AND PAY FOR ALL THE DAMAGE TO THE CAR AND STILL DON'T KNOW WHAT THE LONG TERM AFFECTS OF THIS CORROSIVE ACID WILL BE. IT LEFT A HUGE ORANGE PUDDLE IN OUR GARAGE FLOOR WHICH WE CAN'T GET RID OF. WE TOOK VIDEO AND PICTURES OF THE DAMAGE TO THE CAR, BATTERY AND GARAGE. THE CRACKED FRONT TRANSAXLE CASING WAS ONLY DIAGNOSED AFTER THEY HAD REPLACED THE SEAL ON THE FRONT AXLE TWICE SINCE IT WAS ALWAYS LEAKING FLUID. THE REAR DIFFERENTIAL HAD THE SEAL REPLACED 2 OR 3 TIMES BUT IT STILL LEAKS. THE FUEL PUMPED FAILED ON OUR CAR LEAVING US STRANDED. WE WERE TOLD THAT THE TRUCK NEEDS TO KEEP A 1/4 TANK OF GAS AT ALL TIMES IN THE TANK SO THAT THIS DOES NOT HAPPEN. THE AIR CONDITIONER HAS NEVER REALLY WORKED WELL ON THIS MODEL, IT APPEARS THAT IT IS UNDERSIZED TO HANDLE THE THERMAL LOAD. WE ALSO HAD TO HAVE THE SPOT WELDS ON THE DOOR JAMS FILED BECAUSE MANY SHARP BURRS EXISTED WHICH WERE A SAFETY HAZARD.*AK

NHTSA ID

723203

Incident

Jan 3, 1999