1996 Chevrolet Suburban Engine Problems

1996 SUBURBAN CAUGHT ON FIRE DURING TRANSPORT DUE TO A MECHANICAL FAILURE. *TS *NM

NHTSA ID

10175389

Incident

Sep 17, 2006

ENGINE STOPS RUNNING WITH NO WARNING. THIS CAN OCCUR WHILE IDLING, ACCELERATING, CRUISE SPEED, ANY TIME OF YEAR, ANY WEATHER CONDITION. SOMETIMES IT WILL RESTART BY SHIFTING TO N AND RE-CYCLING IGNITION SWITCH WITHOUT HAVING TO STOP OR LEAVE ROAD. SOMETIMES, AS IS THE PRESENT CASE, IT WILL NOT RESTART. I HAVE OWNED THIS VEHICLE SINCE NEW. THIS HAS BEEN AN ONGOING PROBLEM BEGINNING AT 80,000 MI. MANUFACTURER EXTENDED WARRANTY TO 120,000 MILES, HAS CONTINUED BEYOND WARRANTY PERIOD AND IS A SOURCE OF SAFETY CONCERN. THIS HAS OCCURRED ON INTERSTATE HIGHWAYS, IN THE MIDDLE OF BUSY (HIGH SPEED INTERSECTIONS). DEALER PERFORMED NUMEROUS ATTEMPTS TO FIX PROBLEM, BUT THEY CONTINUED. I HAVE HAD THIS VEHICLE TO THE DEALER MORE TIMES THAN I CAN COUNT. I HAVE HAD ASSISTANCE FROM OTHER PROFESSIONAL SOURCES (AFTER THE WARRANTY PERIOD WAS OVER AND WAS CONVINCED THAT DEALER/MFG. COULD NOT OR WOULD NOT FIX THE PROBLEM. I HAVE REPLACED FUEL INJECTION PUMP 2 TIMES MINIMUM, HAVE REPLACED PMD/FSD AT LEAST 5 TIMES, REPLACED AUXILIARY/LIFT PUMP TWO TIMES, HAVE DRAINED AND CLEANED FUEL TANK 2 TIMES. MOST RECENT INJECTION PUMP REPLACEMENT WAS IN AUG/SEPTEMBER 05 (7000 MILES AGO). I HAVE SPENT AT LEAST $5000 TRYING TO FIX THIS PROBLEM. ENGINE STOPPED LAST MONDAY AND WILL NOT RESTART. AM SURPRISED NO COMPLAINT HAS BEEN FILED BEFORE NOW.*JB

NHTSA ID

10152834

Incident

Mar 11, 2006

Mileage

80,000 mi

1996 CHEVROLET SUBURBAN DEVELOPED PROBLEMS WITH THE BRAKES, INTAKE MANIFOLD, ENGINE COOLING, TRANSMISSION, TIRES, FUEL INJECTORS, FUEL CONSUMPTION AND WIPERS.*MR CONSUMER STATED THAT THE DEALER DID NOT DO ANYTHING BUT TAKE THE BATTERY CABLE OFF TO RESET THE COMPUTER AND THE BRAKES WERE NEVER LOOKED AT. *TT

NHTSA ID

10130223

Incident

Dec 18, 2004

I HAVE REPLACED THE INTAKE MANIFOLD GASKET TWICE NOW FOR MY 1996 CHEVROLET SUBURBAN. BOTH TIMES IT HAS COST ME OVER $650.00. BOTH MECHANICS TOLD ME THAT THEY SEE THESE AT LEAST TWICE A WEEK ON THE 5.7 ENGINES. THEY KNEW EXACTLY WHAT WAS WRONG. THEY ACTUALLY LAUGHED WHEN I ASKED THEM IF IT WAS SET UP AS A RECALL ITEM FOR THIS ENGINE. *JB

NHTSA ID

10074735

Incident

Dec 15, 2003

Mileage

97,000 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

I HAVE OWNED 2 1996-1997 CHEVROLET SUBURBAN AND HAVE HAD THE INTAKE MANIFOLD LEAK ON BOTH AT ABOUT 85000 MILES. I DID A LITTLE LOCAL RESEARCH AND FOUND THAT THIS IS A VERY COMMON PROBLEM FOR THE VORTEC 5.7 ENGINE. WHEN I CALLED THE DEALERSHIP ABOUT A COOLANT LEAK FROM THE ENGINE AREA, THE SERVICE WRITER SAID THIS WAS MOST LIKELY THE INTAKE MANIFOLD BECAUSE THEY GET THAT ALL THE TIME. TOAY, I NOTICED A COOLANT PUDDLE IN MY DRIVE WAY AND UPON LOOKING INTO IT, MY LATEST 1996 SUBURBAN WITH A VORTEC 5.7 IS LEAKING AT THE INTAKE MANIFOLD. THIS IS A COSTLY PROBLEM TO THE CONSUMER. IT COSTS APPROXIMATELY $500.00 TO HAVE THIS DONE. I NOW MUST MAKE THE DECISSION TO HAVE IT FIXED AT THE DEALER FOR $500 OR TO DO IT MYSELF FOR ABOUT $150.00 AND A DAY OF HEADACHES. *AK

NHTSA ID

10072711

Incident

May 15, 2004

Mileage

115,000 mi

LATENT DEFECTS AND THE GMC SUBURBAN.*MR THE CONSUMER HAS EXPERIENCED SEVERAL PROBLEMS WITH VEHICLE. THE FRONT OUTPUT SHAFT SEALS HAD TO BE REPLACED, THE INTAKE MANIFOLD GASKET HAD TO BE REPLACED, AND THE AC HEATER KNOB HAD TO BE REPLACED. WHEN THE DEALER WAS NOTIFIED THEY FAIL TO FIX PROBLEMS AND HE CONSUMER HAD TO PAY AT THERE OWN EXPENSE. PLEASE RESPOND PROMPTLY IN HELPING TO RESOLVE MATTER. *CB

NHTSA ID

10042136

Incident

Oct 30, 1998

Mileage

35,963 mi

CONSUMER NOTICED A LARGE PUDDLE OF ANTI-FREEZE UNDER VEHICLE, LEAKING BETWEEN INTAKE MANIFOLD AND EXHULST. *AK

NHTSA ID

10032060

Mileage

56,502 mi

CONSUMER STATES THAT WHILE DRIVING AT ANY SPEED AND WITHOUT WARNING THE VEHICLE WILL SHUT OFF CAUSING CONSUMER TO PULL OVER. DEALER NOTIFIED. MR

NHTSA ID

8024160

Incident

Nov 20, 2002

CONSUMER STATES THE ENGINE GASKET AND THE INTAKE MANIFOLD ARE DETERIORATE. DEALER HAS INSPECTED AN REPLACED PARTS. PLEASE PROVIDE FURTHER INFORMATION. MR

NHTSA ID

8022609

Incident

Nov 12, 2002

1) MAJOR COOLANT LEAK FROM INTAKE/CYL HEAD GASKET (LEFT REAR OF MOTOR) (2) ENGINE TROUBLE LIGHT INDICATES TC 1870 CODE PROBLEM IN TRANSMISSION VALVE BODY (3)WINDSHIELD WIPERS WORK INTERMITENTLY SAFETY HAZARD (4) A/C DASH LIGHTS CYCLE ON AND OFF WHEN A/C BUTTON IS PUSHED ON BUT FAN MOTOR IS SHUT OFF. ALL PROBLEMS ARE "COMMON" PER DEALERSHIP SERVICE WRITER

NHTSA ID

747054

Incident

Jun 16, 2001

OUR ASE MECHANIC STATES THEY HAVE REPLACED ~35-40 SIMILAR CHEV SUBURBAN RADIATOR FAILURES IN PAST 24 MONTHS IN THEIR SHOP (DOCUMENTATION ON REQUEST). THESE HAVE BEEN ASSOCIATED WITH WATER PUMP FAILURES, INTAKE MANIFOLD LEAKS AND OCC. HEAD GASKET FAILURES WHEN COOLANT HAS LEAKED OVER ENGINE. AMONG ASE MECHANICS IN OUR AREA THIS IS A WELL-KNOW, "LEMON" DESIGN FAILURE WHICH WILL COST ME $900 TO REPAIR. *AK

NHTSA ID

742539

Incident

Mar 15, 2001

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

NHTSA ID

556154

Incident

Sep 1, 2000

THE TRANSMISSION'S HOUSING WAS TOO THIN AND CRACKED, THE CATALYTIC CONVERTER CRACKED IN HALF (NOT RUSTED) THE EXHAUST ASSEMBLY CRACKED IN HALF (NOT RUSTED), CHEVROLET WAS CONTACT AND SAID VEHICLE WAS OUT OF WARRANTY AND IT WASN'T THERE PROBLEM. WE'VE KEPT ALL DEFECTIVE PARTS AND CHEVROLET DOESN'T WANT TO LOOK AT THEM.

NHTSA ID

733583

Incident

Jun 15, 2000

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

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

ENGINE IDLES VERY ROUGH & MISSES--PCM REFLASHED BY DEALER WITH NO IMPROVEMENT. *AK

NHTSA ID

725938

Incident

Nov 1, 1998

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

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

PINION SEAL ON REAR DIFF. LEAKED AT 36K MILES, FUEL INJECTORS CLOGGED AT 40K AND INOPERABLE OXYGEN SENSOR. BATTERY LEAKED AT SIDE TERMINAL (38K MILES), CORRODED BATTERY CABLES AND SHELF. WINSHEILD WIPERS DO NOT GO ALL THE WAY DOWN TO THE STARTING POSITION WHEN TURNED OFF. CURRENTLY HAVING PROBLEMS WITH STARTING THE VEHICLE. STARTER WAS CHECKED AND IS O.K. PROBABLY ELECTRICAL, DUE TO LEAKING BATTERY OR A COMPUTER PROBLEM.

NHTSA ID

718790

Incident

Feb 7, 2000

ENGINE CUTS OFF WITHOUT WARNING, CAUSING ALL POWER STEERING AND ELECTRICAL POWER TO GO OUT. ALSO. DEALER HAS SEEN VEHICLE 5 TIMES, AND HAS CHANGED FUEL PUMP NUMEROUS TIMES. BUT PROBLEM STILL EXISTS. *AK

NHTSA ID

856128

WHILE DRIVING AT VARIOUS SPEEDS ON THE HIGHWAY, VEHICLE WOULD SHUT OFF OR STALL OUT WITHOUT WARNING. WHEN TRYING TO PASS TRUCKS OR VEHICLES, VEHICLE STALLED. WAS NEARLY RUN OVER BY 18-WHEELER. WHEN IT HAPPENED, VEHICLE HAS BEEN TOWED TO DEALERSHIP NUMEROUS TIMES. MECHANIC REPLACED THE DRIVER (5), INJECTOR PUMP(4), LIFTER PUMP(2), MAIN BRAIN(5) & THE RECEIVER SENSORS(5). THE COMPUTER SYSTEM WOULD SOMETIMES ALLOW VEHICLE TO RESTART. PROBLEM IS NOT GETTING BETTER. VEHICLE WAS BOUGHT NEW. OWNER VERY UPSET. DEALERSHIP WORKING WITH OWNER. WARREN ROOSEVELT DEALERSHIP IN CANAJOHARIE NY. *AK

NHTSA ID

851885

Incident

Aug 10, 1999

NO SUMMARY

NHTSA ID

711635

Incident

Aug 8, 1998

MANIFOLD PIPE EXPERINCED STRESS CRACK CAUSING EXCESSIVE NOISE AND FUMES TO ENTER PASSENGER COMPARTENT OF VEHICLE. *YC

NHTSA ID

548481

Incident

Jul 26, 1999