1996 Pontiac Sunfire Problems, Complaints & Recalls

Problem: Certain passenger vehicles and mini vans have lower pinion bearings in the power rack and pinion assembly in which the retainer tabs were not crimped properly. These and some other retainers used in vehicles assembled between january 1, 1996 and october 31, 1997, could fail and permit the ball bearings to escape.

Risk: If this occurs, the pinion shaft can be forced upward during left turns and back down as the steering wheel is moved back and to the right. If the pinion shaft moves further, the driver will need to exert more effort to turn the steering wheel, similar to a vehicle without power assisted steering. If the pinion shaft moves even further, the driver will require much higher effort to turn left and may not be able to turn the wheel as much as intended. With the maximum pinion shaft movement, which requires internal gear component damage, the driver can encounter high resistance to turning left, followed by unintended power assist to the right. In any of these conditions, a crash could occur.

Fix: Dealers will install a new lower pinion bearing unless inspect of the existing bearing indicates that replacement of the gear assembly is necessary. Owner notification began january 24, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020, pontiac at 1-800-762-2737, or oldsmobile at 1-800-442-6537.

Problem: On certain passenger vehicles. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts.

Risk: If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed.

Fix: Dealers will install a relay kit in these vehicles to prevent high current from flowing through the ignition switch. Owner notification began march 27, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1-800-222-1020, pontiac at 1-800-762-2737, buick at 1-800-521-7300, or oldsmobile at 1-800-442-6537.

Problem: Vehicle description: passenger vehicles. One of the rear suspension trailing arm bolts can fatigue and break.

Risk: If this were to occur while the vehicle was in motion, a loss of vehicle control can occur, increasing the risk of a crash.

Fix: Dealers will replace the rear suspension trailing arm fasteners.

Problem: Vehicle description: passenger vehicles. Because of certain calibrations in the air bag's sensing and diagnostic module, an inadvertent air bag deployment could occur in a low speed crash or when an object strikes the floor pan.

Risk: Air bags deploy with great force and can seriously injure unrestrained occupants who are too close to them.

Fix: Dealers will recalibrate the air bag sensing and diagnostic module.

Problem: Vehicle description: passenger vehicles. These vehicles were built with the potential for the interior lamps to come on unexpectedly while the vehicles are being driven. This does not meet the requirements of fmvss no. 101, "controls and displays."

Risk: The interior lamps coming on unexpectedly could startle a driver causing a momentary loss of control increasing the risk of a vehicle accident.

Fix: Dealers will run a diagnostic test on the lamp control module and, if necessary, replace it.

Problem: The front and/or rear hazard warning lamps (four-way flashers) do not flash when the hazard switch is activated. This fails to comply with fmvss no. 108, "lamps, reflective devices, and associated equipment."

Risk: If these lamps were not flashing, other vehicles would not be aware that this vehicle was stopped increasing the risk of an accident.

Fix: Dealers or vehicle owners will inspect for proper function of the hazard warning lamps. If necessary, dealers will replace the hazard lamp switch.

Problem: The accelerator control cable could have been kinked during assembly causing high accelerator pedal effort, sticking accelerator control cable, or a broken accelerator control cable.

Risk: If the accelerator control cable sticks or breaks, unwanted acceleration and/or loss of throttle control can result increasing the risk of a vehicle accident.

Fix: Dealers will replace the accelerator control cable assembly.