Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 25 of 201 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
Engine And Engine Cooling. Review the 39 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Air Bags. Review the 33 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
30 crash reports11 fire reports18 injury reports
What owners actually said
201 reports
Mileage unknown · Jan 15, 2004
Air BagsCrashInjury
I WAS A PASSENGER IN THE CAR, SO I DON'T KNOW SPECIFIC MILEAGE, OR VIN NUMBER. THE CAR HAD APPROXIMATELY 80,000 MILES ON IT. THE ACCIDENT OCCURRED ON JULY 5, 2002. IT WAS A FAIRLY LOW SPEED CRASH, MYE ESTIMATE IS WE WERE GOING ABOUT 30 MPH AT IMPACT. WE STRUCK THE CAR IN FRONT OF US. THE AIRBAG DEPLOYED IN MY FACE. I WAS …
Read full complaint
I WAS A PASSENGER IN THE CAR, SO I DON'T KNOW SPECIFIC MILEAGE, OR VIN NUMBER. THE CAR HAD APPROXIMATELY 80,000 MILES ON IT. THE ACCIDENT OCCURRED ON JULY 5, 2002. IT WAS A FAIRLY LOW SPEED CRASH, MYE ESTIMATE IS WE WERE GOING ABOUT 30 MPH AT IMPACT. WE STRUCK THE CAR IN FRONT OF US. THE AIRBAG DEPLOYED IN MY FACE. I WAS WEARING MY SEAT BELT AND WAS NOT SITTING PARTICULARLY CLOSE TO THE AIRBAG. THE FORCE OF THE IMPACT FROM THE AIR BAG, BROKE MY NOSE AND RESULTED IN PERMANENT DAMAGE TO MY EYES. I WAS THE ONLY PERSON INJURED IN THE ACCIDENT.
NHTSA ODI #10070415
Mileage unknown · Jan 6, 2004
Exterior Lighting
THE HEADLIGHTS GO OUT UNEXPECTEDLY WHEN THE DIMMER SWITCH IS MOVED TO OR OPERATED IN LOW BEAM. FAULTY DIMMER SWITCH. I HAD TO PUT A PIECE OF PAPER IN THE SWITCH SO I WOULDN'T HIGH BEAM EVERYONE ON THE WAY HOME ONE NIGHT.*AK
NHTSA ODI #10052526
Mileage unknown · Dec 3, 2003
Engine And Engine Cooling
FAILURE OF HEAD GASKET AT LESS THAN 64,000 MILES. I UNDERSTAND THAT THIS IS A COMMON COMPLAINT WITH THE SUNFIRE MODEL ALTHOUGH THERE HAS BEEN NO OFFICIAL RECALL FOR THIS. *NLM
NHTSA ODI #10049089
150,000 miles · Nov 30, 2003
Engine And Engine Cooling
HEAD GASKET ON MY 96 PONTIAC SUNFIRE BLEW AND CAUSED MY CAR TO STALL IN TRAFFIC AND ALMOST CAUSED AN ACCIDENT WITH MY FAMILY ABOARD. MY CAR WENT FROM 195 OPERATING TEMP TO 260 WITH IN 1 MINUTE. THE CAR COULD HAVE CAUGHT FIRE AND CAUSED TREMENDOUS INJURIES.*AK
NHTSA ODI #10048886
119,813 miles · Sep 2, 2003
Electrical System
CAR TURNS OVER BUT WILL NOT START.BROUGHT IT BACK TO DEALER AND THEY REPLACED THE CAMSHAFT SENSOR. GOT THE CAR BACK TWO DAYS LATER AND THE SAME THING HAPPENED. BROUGHT BACK TO DEALER AND THEY SAID IT WAS THE OEM SERCRITY SYSTEM. TOOK BACK AND ARE STILL HAVING PROBLEMS STARTING ALL THE TIME.*AK
NHTSA ODI #10037080
Mileage unknown · Aug 28, 2003
Electrical SystemFire
WHILE PUTTING THE KEY INSIDE THE IGNITION VEHICLE WOULD NOT START. DRIVER TOOK KEY OUT OF THE IGNITION AND STEERING COLUMN STARTED SMOKING. VEHICLE CAUGHT ON FIRE. CONSUMER CONTACTED DEALER. *AK
NHTSA ODI #10037805
Mileage unknown · Aug 15, 2003
Electrical SystemEngine And Engine Cooling
HEADLIGHTS GO OUT INTERMITTENTLY WHILE DRIVING. THIS HAS BEEN REPAIRED NUMEROUS TIMES, THE PROBLEM IS A SPLICE IN THE WIRING. *AK THE HIGH BEAMS WERE INOPERATIVE AND THE DAYTIME RUNNING LIGHTS FLASHED WHILE DRIVING. THE DEALER REPLACED THE INSTRUMENT PANEL CLUSTER. THE VACUUM ACTUATOR WAS STICKING WHICH CAUSED THE HEATER CO…
Read full complaint
HEADLIGHTS GO OUT INTERMITTENTLY WHILE DRIVING. THIS HAS BEEN REPAIRED NUMEROUS TIMES, THE PROBLEM IS A SPLICE IN THE WIRING. *AK THE HIGH BEAMS WERE INOPERATIVE AND THE DAYTIME RUNNING LIGHTS FLASHED WHILE DRIVING. THE DEALER REPLACED THE INSTRUMENT PANEL CLUSTER. THE VACUUM ACTUATOR WAS STICKING WHICH CAUSED THE HEATER CONTROL NOT TO BLOW ON THE SETTING SELECTED. THE MUFFLERS HANGER BROKE AND THE BAFFLES WERE LOOSE WHICH CAUSED RATTLING AT IDLE. *SCC *NLM
NHTSA ODI #10026652
Mileage unknown · Aug 7, 2003
Electrical SystemFire
WHEN THE CONSUMER ATTEMPTED TO START THE VEHICLE THE IGNITION FAILED TO TURN, WHEN ALL OF A SUDDEN SMOKE EMITTED FROM THE STEERING COLUMN. THE CONSUMER CONTACTED THE FIRE DEPARTMENT AND THEY DISCONNECTED THE CABLE AND BATTERY. THE KEY NO LONGER TURNED THE IGNITION, THE CAR WAS SENT TO THE DEALERSHIP , HOWEVER THEY REFUSED TO FI…
Read full complaint
WHEN THE CONSUMER ATTEMPTED TO START THE VEHICLE THE IGNITION FAILED TO TURN, WHEN ALL OF A SUDDEN SMOKE EMITTED FROM THE STEERING COLUMN. THE CONSUMER CONTACTED THE FIRE DEPARTMENT AND THEY DISCONNECTED THE CABLE AND BATTERY. THE KEY NO LONGER TURNED THE IGNITION, THE CAR WAS SENT TO THE DEALERSHIP , HOWEVER THEY REFUSED TO FIX THE VEHICLE, BECAUSE THEY CLAIMED THAT SMOKING OF A VEHICLE WAS NOT UNDER WARRANTY. THE FIRE DEPARTMENT HAD TO FAX THEM A NOTICE THAT IS WAS A FIRE. DEALER NOTIFIED. *AK *CB *JB
NHTSA ODI #10027189
156,000 miles · Jul 28, 2003
Electrical SystemExterior LightingVisibility
THE IGNITION SWITCH HAD A SHORT CIRCUIT WHICH CAUSED THE VEHICLE NOT TO START. AFTER THE IGNITION WAS REPAIRED IT STILL DIDN'T WORK PROPERLY. THE HEAD LIGHT (HIGH AND LOW BEAMS) FAILED. THE HORN FAILED. THE WIPER FAILED. *JB *CB *NLM
NHTSA ODI #10011186
Mileage unknown · May 29, 2003
Electrical SystemEngine And Engine CoolingExterior Lighting
-THE HORN ON 1996 PONTIAC SUNFIRE HAS QUIT WORKING AND BEEN REPAIRED THREE TIMES. THE PEOPLE AT THE SHOP SAID THAT IT WAS GETTING WET APPARENTLY EVERYTIME I WENT THROUGH WATER BECAUSE OF IT BEING POINTED DOWNWARD. -THE MUFFLER HAS BEEN FIXED THREE TIMES -THERE ARE MORE THAT I CAN NOT REMEBER RIGHT OFF HAND -THEIR IS AN ELE…
Read full complaint
-THE HORN ON 1996 PONTIAC SUNFIRE HAS QUIT WORKING AND BEEN REPAIRED THREE TIMES. THE PEOPLE AT THE SHOP SAID THAT IT WAS GETTING WET APPARENTLY EVERYTIME I WENT THROUGH WATER BECAUSE OF IT BEING POINTED DOWNWARD. -THE MUFFLER HAS BEEN FIXED THREE TIMES -THERE ARE MORE THAT I CAN NOT REMEBER RIGHT OFF HAND -THEIR IS AN ELECTRICAL PROBLEM WITH THE WHOLE CAR. THE LIGHT ON THE RADIO TIME AND STAION DISPLAY HAS NOT WORKED SINCE I BOUGHT IT, THE DRIVER'S REAR DOOR LIGHT HAS NOT COME ON, THE PASSENGER REAR WINDOW LETS DOWN BUT WILL NOT LET UP WHEN NEEDED SINCE RIGHT AFTER I GOT THE CAR, THE LIGHTS IN THE DASHBOARD GO ON AND OFF WITHOUT EVEN BEING TOUCHED, WHILE RIDING DOWN THE ROAD, THE WIDSHIELD WIPERS WILL JUST COME ON WITHOUT BEING TURNED ON AND THEN STOP HALFWAY DOWN IMPAIRING VISION, THE PASSENGER REAR TAIL LIGHT BLOWS ALL OF THE TIME, IT HAS NEVER STAYED WITH A BULB THAT WORKS, ETC. -THE VALVE COVER GASKET LEAKS AND HAS LEAKED SINCE I GOT IT -THE GAS LIGHT WILL NOT TELL YOU WHEN YOU ARE RUNNING LOW ON FUEL -THE RADIO WILL EAT YOUR TAPES SINCE I GOT THE CARTHE TRANSMISSION HAS BEEN REPLACE ON THE CAR WITH LESS THAN 80,000 MILES ON IT -THE RACK AND PINION HAD TO BE REPLACED A FEW YEARS AGO ALONG WITH THE COMPLETE BRAKE SYSTEM THE POWER STEERING HAS LEAKED FLUID AND WILL STOP TURNING IN THE MIDDLE OF A TURN. I HAVE ALMOST WRECKED ON IT SVERAL TIMES BECAUSE OF IT AND THE BRAKES. -THE AIR CONDITIONING COMPRESSOR WORKS WHEN IT GETS READY TO IF EVEN THEN AND HAS ALWAYS DONE THAT.
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.
Consequence & remedy
Consequence: 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.
Remedy: 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.
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.
Consequence & remedy
Consequence: IF THE SWITCH IS DAMAGED, A FIRE COULD OCCUR IN THE STEERING COLUMN, EVEN WITH THE ENGINE OFF AND THE KEY REMOVED.
Remedy: 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.
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.
Consequence & remedy
Consequence: AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED OCCUPANTS WHO ARE TOO CLOSE TO THEM.
Remedy: DEALERS WILL RECALIBRATE THE AIR BAG SENSING AND DIAGNOSTIC MODULE.
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."
Consequence & remedy
Consequence: THE INTERIOR LAMPS COMING ON UNEXPECTEDLY COULD STARTLE A DRIVER CAUSING A MOMENTARY LOSS OF CONTROL INCREASING THE RISK OF A VEHICLE ACCIDENT.
Remedy: DEALERS WILL RUN A DIAGNOSTIC TEST ON THE LAMP CONTROL MODULE AND, IF NECESSARY, REPLACE IT.
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."
Consequence & remedy
Consequence: IF THESE LAMPS WERE NOT FLASHING, OTHER VEHICLES WOULD NOT BE AWARE THAT THIS VEHICLE WAS STOPPED INCREASING THE RISK OF AN ACCIDENT.
Remedy: DEALERS OR VEHICLE OWNERS WILL INSPECT FOR PROPER FUNCTION OF THE HAZARD WARNING LAMPS. IF NECESSARY, DEALERS WILL REPLACE THE HAZARD LAMP SWITCH.
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.
Consequence & remedy
Consequence: 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.
Remedy: DEALERS WILL REPLACE THE ACCELERATOR CONTROL CABLE ASSEMBLY.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3
DP03007 · Unintended Vehicle Acceleration
Opened Oct 14, 2003 · Closed Jan 30, 2004
Status: closed (inferred from source dates) · Fuel System, Other:delivery
ON SEPTEMBER 23, 2003, THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) RECEIVED A LETTER DATED SEPTEMBER 8, 2003 FROM MR. DONALD FRIEDMAN, PETITIONING THE AGENCY TO OPEN A DEFECT INVESTIGATION INTO UNINTENDED ACCELERATION INVOLVING [MODEL YEAR] 1996 AND 1997 GENERAL MOTORS J-CARS.IN SUPPORT OF HIS PETITION, MR. FRIEDMAN CITED A REPORT HE RECEIVED FOR GM SHOWING IT HAD RECEIVED FAR MORE REPORTS OF ALLEGED UNINTENDED ACCELERATION FOR THESE MODELS THAN FOR OTHERS.AFTER ASSESSING THE DATA CLAIMED BY THE PETITIONER TO JUSTIFY HIS REQUEST, ODI FOUND NO INDICATION THAT DEFECT TREND RELATED TO THE PETITIONER'S ALLEGATIONS EXISTS AT THIS TIME.THEREFORE, THERE IS NO REASONABLE POSIBILITY THAT AN ORDER CONCERNING THE NOTIFICATION AND REMEDY OF A SAFETY-RELATED DEFECT WOULD BE ISSUED AS A RESULT OF GRANTING MR. FRIEDMAN'S PETITION.CONSEQUENTLY, IN VIEW OF THE NEED TO ALLOCATE AND PRIORITIZE NHTSA'S LIMITED RESOURCES TO BEST ACCOMPLISH THE AGENCY'S SAFETY MISSION, THE PETITION IS DENIED.FOR ADDITIONAL INFORMATION CONCERNING THIS ANALYSIS, PLEASE REFER TO THE ATTACHED FEDERAL REGISTER NOTICE.
PE02001 · Fire In Steering Column Area
Opened Jan 3, 2002 · Closed Mar 15, 2002
Status: closed (inferred from source dates) · Electrical System
No summary supplied.
EA98001 · Oversensitive Air Bag Deployments
Opened Jan 23, 1998 · Closed Jul 31, 1998
Status: closed (inferred from source dates) · Air Bags
There is no summary currently available
1996 Pontiac Sunfire Problems, Complaints & Recalls | Skip That Year
Illustration