1996 GMC Safari Problems

What owners report

Owners of this model year most often write about the front torsion bars breaking without warning, usually while driving or just after the vehicle has been parked, and about windshield wipers that stop or start on their own. Brake complaints are also common, with reports of the pedal going to the floor or of the ABS system engaging on dry pavement. Many of the sampled reports come in between roughly 80,000 and 130,000 miles.

1. 1
   Suspension

   Front torsion bar breaks and front end drops

   • 22 complaints (16%)
   • median 99,632 mi at 7.9 yrs old (6 state mileage, few)
   • filed 2000–2006

   Complaints describe a loud bang or boom, sometimes followed by the front of the van dropping onto the tires and the vehicle pulling sharply to one side. Some owners say it happened while driving, others while parked or backing out of a driveway, and several were told both torsion bars should be replaced together. Owners report that replacement bars differ from the originals and that a revised mounting kit is used, and some say they were told the failure is a known or design-related condition rather than normal wear. Reported from roughly 60,000 to over 170,000 miles, with many in the 93,000 to 110,000 mile range and no prior warning described.

   What to check: Have a shop inspect both front torsion bars, their mounts and the knuckle area for rust or cracking, and ask whether either bar has already been replaced. Rock the van and listen for a bang, and check for uneven front ride height.

   2 excerpts from owner complaints in NHTSA records

   “Left side torsion bar snapped when driving. The repair shop changed both left and right side torsion bars and arms even though the right side was fully functional. Gm's parts department stated that this was a manufacturing design problem and thus I had to change both sides. This has apparently been a problem with other same model cars as well. I feel that if that is the case, then they should recall all cars because it poses a serious safety hazard.”

   NHTSA complaint #10071370, filed 2004-01, 94,000 miles

   “While traveling at 65 MPH drivers side torsion bar inexplicably and without warning broke. Entire vehicle shuddered and pulled sharply to the left. Fortunately for my passengers and myself I was able to quickly regain control and come to a safe stop. This is a serious safety issue. Such a failure could easily result in serious injury or death. Since the torsion bar failure I have been told by different mechanics they break all the time and it is a design flaw . …”

   NHTSA complaint #10032813, filed 2003-08, 103,265 miles
2. 2
   Brakes

   Soft or low brake pedal, ABS engaging when it should not

   • 18 complaints (13%)
   • median 109,500 mi at 7.6 yrs old (4 state mileage, few)
   • 4 mention a crash, fire or injury
   • filed 1996–2005

   Complaints describe a pedal that sinks toward the floor, longer stopping distances, and ABS kicking in on dry pavement, sometimes with a light on the dash. Owners report repeated parts replacement including ABS modules, sensors, master cylinder, calipers and rotors, and some say dealers could not duplicate the problem. A few reports describe a brake line worn through where another line was routed against it. Mostly reported above roughly 75,000 miles, with several between 100,000 and 140,000 miles, and described as intermittent.

   1 related service bulletin

   What to check: Check pedal feel with the engine running and look for ABS warning lights, and have the brake lines inspected for chafing or rust. Ask for service records showing whether the ABS module or sensors have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Since the middle of last year, we experienced a problem w/ABS brakes. When you would slow down & get to about 20 MPH, the van would start to lock up rendering the vehicle out of control & unable to stop. We took it to our usual mechanic who determined the sensor on the driver side was bad & replaced it. That lasted about 6 months & we had the same problem reoccur. Again, our mechanic looked at it (pulling his hair out mind you) & determined that there was unequal voltage, so he replaced both sensors. …”

   NHTSA complaint #10070281, filed 2004-01, 109,000 miles

   “My vehicle was moving about 10 m.p.h. In preparation to stop behind several vehicles at a red light. I applied my brakes in an attempt to come to a complete stop; however, the brakes failed to engage. I then put full pressure on the brake pedal. The pedal went down almost to the floor, but the brakes failed to stop the vehicle. As a result of this brake failure, my vehicle struck the vehicle in front of it which in turn struck a third vehicle. My vehicle was towed to a mechanic who was able to duplicate the failure. …”

   NHTSA complaint #753776, filed 2001-10
3. 3
   Visibility (wipers, defrost, mirrors)

   Windshield wipers stop or run intermittently

   • 22 complaints (16%)
   • median 79,500 mi at 7.2 yrs old (4 state mileage, few)
   • filed 1998–2004

   Owners describe wipers that quit in rain, come on by themselves, or work only some of the time, with the motor sometimes still audible. Some say the blades stop mid-swipe or that a fuse blows repeatedly, and a few report repairs where the problem came back. Several complaints note that recall 03V159000 covers this symptom on related vehicles but that their van was not included. Reported across a wide mileage range, often at highway and city speeds in wet weather, with no warning before the wipers stop.

   Recall 03V159000

   What to check: Run the wipers at every speed and in every delay setting, including in wet conditions if possible, and ask whether the wiper motor or controller board has been replaced under the recall.

   2 excerpts from owner complaints in NHTSA records

   “The windshield wipers failed intermittently, never know when they will work, or won't work. 1996 Gmc jimmy's had same problem, which was recalled and fixed by Gmc dealers, why haven't the safaris? I have seen several complaints that have been reported, this is a safety hazard!!!!!! Some times they work and sometimes they don't. I have had to drive in the rain w/o wipers, and it's dangerous!!!!! Also the hydraulics that hold the top half of teh rear hatch door open, have failed three times. We had the dealer replace them twice, but at over $100. …”

   NHTSA complaint #721381, filed 2000-04

   “Intermittently rear windshield wipers become inoperable, obstructing driver's view. The accelerator cable was replaced twice. The alternator was replaced three times. The water pump was replaced twice. The driver's side power window motor was replaced and the passenger side needs to be replaced. The driver's side seat motor failed. The hatch failed. The rear captain chairs seat belts broke.”

   NHTSA complaint #10038013, filed 2003-10, 93,000 miles
4. 4
   Electrical system

   Fuel pump fails or stops delivering fuel

   Mentioned in 4 of 60 sampled complaints

   Owners report vans that crank but will not start or stall, with the fuel pump found not to be pumping. In some complaints the pump showed electrical damage or heat damage at its connection, and one owner reported a melted hose at the pump. A related complaint describes rough idle and misfiring traced to sticking fuel injectors, with a service bulletin cited for the injector system. Reported in the 87,000 to 98,000 mile range in the sample, typically as a no-start or stall rather than a gradual decline.

   What to check: Ask whether the fuel pump and filter have been replaced and listen for a prime cycle at key-on. Have a shop check fuel pressure and inspect the pump wiring and connector for heat damage.

   2 excerpts from owner complaints in NHTSA records

   “The consumer 1996 Gmc Safari van electrical problem with fuel pump. The fuel pump did not pump fuel. The fuel pump suffered electrical damage. The fuel filter was changed when the rebuilt engine was placed in the vehicle. The main bearing was shot.”

   NHTSA complaint #10112837, filed 2005-02, 87,000 miles

   “Problem with 1996 Gmc Safari van not starting. The mechanic found the fuel pump was not pumping fuel. Upon retrieving the fuel pump from the gas tank, he found it to have suffered severe electrical damage. The actual failure was not the fuel pump, but because it generated enough heat to melt the hose coming from the pump along the connection. The consumer also stated he had to have a rebuilt engine installed after the first engine failed with only 87,000 miles.”

   NHTSA complaint #10115064, filed 2005-02, 87,000 miles
5. 5
   Body and structure

   Rear hatch and door hardware failures

   Mentioned in 4 of 60 sampled complaints

   Complaints describe the rear hatch struts losing the ability to hold the door open, a hatch that fails or will not latch, and body cracks at the base of the back door post. One owner also reports a sliding door that does not sit on its track and needed repeated repairs. Owners describe these as trim and hardware failures that sometimes led to the door being unusable. Reported across the model year's life, from low mileage up to roughly 93,000 miles, often noticed during normal loading and unloading.

   What to check: Open and close the rear hatch and sliding door several times, check that the struts hold the hatch up, and look at the door post base and sheet metal for cracks.

   2 excerpts from owner complaints in NHTSA records

   “Sliding door does not sit on track properly. Intermittently door is inoperable. Dealer has repaired vehicle more than fifteen times. Consumer states door will not open without banging, consumer listed that 2 people had been injured.”

   NHTSA complaint #888968, filed 2001-05

   “Back door post broken at its base, thru inside c channel (outside skin still intact). Exact failure time not known, just noticed crack when entering car. Apparent failure from metal fatigue; no known impact or cause of failure. Gmc has denied warranty claim saying that it is sheet metal failure, which is not covered. I'm contending that is a fialure to a structural member and therefore covered. Is there any record of similar failures on any Gmc product that may utilize the same door?”

   NHTSA complaint #715830, filed 1999-12

Buying note. These vans are old enough that condition and maintenance history matter more than the model year itself, so budget for a suspension and brake inspection before purchase. Pay particular attention to the front torsion bars and wiper operation, since those draw the most owner reports.

Summary written with AI from a sample of 60 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.