1996 Chevrolet Pickup Problems

What owners report

Complaints on this model year center on windshield wipers that stop or run intermittently, leaving drivers without wipers in rain; many owners say the wiper recall did not cover their truck or that the dealer declined the repair. Brake complaints describe a pedal that sinks toward the floor and ABS that does not respond, along with rusted steel brake lines. A smaller group reports engine stalling, mostly tied to fuel-injection or pump-driver problems.

1. 1
   Visibility (wipers, defrost, mirrors)

   Windshield wipers quit or run intermittently

   • 15 complaints (25%)
   • median 38,000 mi at 8.7 yrs old (1 states mileage, few)
   • filed 1999–2004

   Owners describe wipers that stop without warning, or that work only on the high setting, often during rain. Several mention a cracked solder joint or worn contacts in the wiper motor or wiring connector; some say the motor must be replaced. According to the complaints, dealers sometimes checked the VIN against a wiper recall and said the truck was not covered, and some owners were told to replace the motor at their own expense. Mileage is mostly not stated; complaints span trucks from a few years old into the 2000s.

   What to check: Cycle the wipers through delay, low and high settings, ideally with the windshield wet, and ask whether the wiper motor or wiring was ever replaced.

   2 excerpts from owner complaints in NHTSA records

   “The vehicle was just recently transfered to my name though I have been the primary driver since the vehicle was purchased in december of 1995. The windshield wipers have failed on numerous occassions. I have had the service station where I trade look at it and unless I want to cover the expense of having the motor replaced they recommended that I jiggle the wire to the wiper box. …”

   NHTSA complaint #766579, filed 2002-09

   “When windshield wipers were turned on they worked and stopped. Now windshield wipers work intermittently. Dealer contacted and is aware of the problem. Vehicle was manufacturered in ontario and does not compy to GM recall. Also steering wheel will pop, and horn will not operate properly. Problem still exists. Provide further information.”

   NHTSA complaint #836379, filed 1999-04
2. 2
   Brakes

   Soft or low brake pedal, weak ABS response

   Mentioned in 5 of 36 sampled complaints

   Complaints describe the brake pedal traveling nearly to the floor and the ABS not grabbing when the pedal is pressed, sometimes on a downgrade or on the first drive of the day after rain. One owner reports a rusted steel brake line with a hole near a frame clamp. Dealers were reported to have replaced ABS parts and lines. Reported at unspecified mileage, often in wet or rainy conditions.

   What to check: Press the pedal firmly with the engine running and check that it holds; have the steel brake lines along the frame inspected for rust before buying.

   2 excerpts from owner complaints in NHTSA records

   “When driving under wet road conditions and putting foot on the brake pedal to stop the truck, it takes longer for the truck to stop, it continues to travel and then stops. It only does this when it rains. The insurance report indicates that there was a high rate of problems with this vehicle.”

   NHTSA complaint #816634, filed 1997-09

   “Driving at approximately 40-60 MPH vehicle will stall out/motor will cut off. Brakes are soft ,no power, has to put in neutral to restart,dealer replaced fuel injection/reprogrammed computer and checked codes.”

   NHTSA complaint #819220, filed 1997-11
3. 3
   Fuel system

   Engine stalls while driving or at idle

   • 5 complaints (8%)
   • typically at 2.7 yrs old
   • filed 1997–2002

   Owners report the engine cutting off without warning at idle or at road speed, which they say also affects power braking and steering. Complaints link the stalling to fuel-injection and injection-pump problems, including the pump-mounted driver on the 6.5L diesel; one owner reports the pump being replaced. Dealers were reported to have replaced injection components and reprogrammed the computer. One complaint cites about 55,000 miles; others do not state mileage.

   What to check: Ask whether the injection pump or pump-mounted driver has been replaced, and test-drive long enough to include idling and steady cruising.

   2 excerpts from owner complaints in NHTSA records

   “See NHTSA item number sb052350. I incurred a $510 repair bill for a known and acknowledge design defect. I contacted the manufacturer for re-imbursement but they have failed to provide any assistance.”

   NHTSA complaint #739689, filed 2001-01

   “Motor will shut off at various times, at idle or while driving, without warning. Truck is used for trailering horses and heavy equipment and the engine shutting down severely effects braking and steerage and is a serious safety hazard. The truck was repaired by the dealership for fuel injection pump problems at 55812 miles with the pump being replaced. …”

   NHTSA complaint #764593, filed 2002-07
4. 4
   Visibility (wipers, defrost, mirrors)

   Door handles and tailgate cables break

   • 7 complaints (12%)
   • median 80,000 mi at 8.3 yrs old (1 states mileage, few)
   • filed 1997–2004

   Owners describe interior and exterior door handles snapping off repeatedly, and in one case a driver's door sagging off its hinges so the window had to be rolled down to get out. Another complaint says the tailgate support cables fray because they are no longer metal. Repairs were mostly done by the owners themselves, according to the complaints. One complaint is at about 80,000 miles; the rest do not state mileage.

   What to check: Open and close every door from inside and outside, check the hinges for sag, and inspect the tailgate cables for fraying.

   An excerpt from owner complaints in NHTSA records

   “The bearings that the rail slides on are comming out due to a bent rail. This causes the seat to be loose and could come off the rails in a collision.”

   NHTSA complaint #744731, filed 2001-04

Buying note. These are older trucks, so condition matters more than the pattern of complaints: test the wipers, brakes and door hardware directly and ask for service records on the fuel-injection system, especially on diesel models.

Summary written with AI from a sample of 36 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.