1996 Isuzu Rodeo Problems

What owners report

Owners of the 1996 Isuzu Rodeo most often write about wheel lug nuts and studs that strip or snap when wheels are serviced, and about rusted-through frames that shops have called not roadworthy. Air bags that did not deploy in frontal impacts are also reported frequently, along with brake symptoms such as soft pedals and ABS warning lights. Many complaints come in at higher mileage, though the frame rust reports often appeared well past 100,000 miles on vehicles that otherwise still ran well.

1. 1
   Wheels

   Wheel lug nuts and studs strip or snap

   • 13 complaints (13%)
   • typically at 3.6 yrs old
   • filed 1998–2004

   Complaints describe lug nuts and wheel studs that strip, crack or break when a wheel is removed for tire rotation or repair, sometimes even when turned by hand. Owners say the studs on some wheels had to be cut off and in some cases the hub or rear axle had to be replaced. When owners raised it with the dealer, the response described in the complaints was that the problem was not known to them or was blamed on the mechanic's use of an air gun. Reported across a wide range of ages and mileages, typically during routine tire service.

   What to check: Have a shop loosen and retorque each wheel by hand during a pre-purchase inspection and look at the studs and nuts for rounding, cracks or thread damage. Ask whether hubs or axles have been replaced because of broken studs.

   2 excerpts from owner complaints in NHTSA records

   “While having tires rotated,the lugs: nuts broke. Hubs also had to be replaced. Manufacturer and dealer deny this is a problem with other Isuzu rodeos, and say the warranty will not pay for the repairs. Therefore they're trying to sock me with the $650 dollar bill. As I can tell by your reports this is a common problem with this type of vehicle, and this should be listed as a defect and the warranty should pay.”

   NHTSA complaint #700378, filed 1998-11

   “For the 2nd time the lugs & studs on the Isuzu Rodeo have either broken/cracked or stripped when a tire roation is being preformed. Both times service representative manuelly tried to remove the lugs . And afterwards tried to tighten the lugs. As a result I have had to replace the entire rear axle - since the studs are built from the inner side outward. Now with several lugs stripped again, I fear I will have to replace the axle again.”

   NHTSA complaint #10098491, filed 2004-11
2. 2
   Air bags

   Air bags did not deploy in a frontal impact

   • 9 complaints (9%)
   • median 149,000 mi at 15.0 yrs old (1 states mileage, few)
   • 9 mention a crash, fire or injury
   • filed 1996–2010

   Complaints describe frontal collisions at speeds from about 15 to 60 mph in which neither the driver nor the passenger air bag deployed. In one case an owner reported an air bag deploying while the vehicle was parked and reversing, leaving a cloud of white powder. Most owners say they had not yet contacted a dealer at the time of the complaint. Reported across many model years of use, with mileage figures in the complaints ranging from about 75,000 to 149,000.

   What to check: Ask whether the air bag system has ever been serviced or diagnosed, and have the air bag warning light confirmed to work at key-on. On a vehicle this age, ask a shop to check for stored air bag fault codes.

   2 excerpts from owner complaints in NHTSA records

   “While driving vehicle, another vehicle pulled out in front of my vehicle which caused me to hit that vehicle head-on and during that time air bag did not deploy; also, replaced oxygen sensor/fuel sending unit/wiring harness processing assembly.”

   NHTSA complaint #803596, filed 1996-12

   “Driving down interstate highway, driver made abrupt turn to avoid collision, SUV ladden with x-mas baggage, began to fish tail. Driver spun wheel other direction and SUV started rolling over. During the rollover there was a collision with a guardrail, during the rollover the driver side roof collapsed on top of driver, killing her by head trauma. No other autos were involved in accident. Air bags never deployed. Husband and two children survived.”

   NHTSA complaint #718607, filed 2000-02
3. 3
   Body and structure

   Frame rust-through

   • 9 complaints (9%)
   • median 151,606 mi at 15.2 yrs old (6 state mileage, few)
   • filed 2010–2014

   Owners describe frames under the vehicle that are heavily rusted, in some cases to the point where mechanics said the vehicle should not be driven. Several complaints tie the rust to road salt in winter and note that fuel lines and brake lines also corroded. Where owners asked the dealer or manufacturer about a frame recall, the response described was that this model year was not included. Often reported above 100,000 miles, repeatedly linked to winter road salt.

   What to check: Put the vehicle on a lift and inspect the frame rails, crossmembers and lines underneath for flaking scale and holes, especially on a vehicle from a salt-belt state. Poke suspect areas with a screwdriver and ask for an inspection report.

   2 excerpts from owner complaints in NHTSA records

   “Hi, I own an Isuzu Rodeo s v6 (year 1996) and after having some problems with the fuel pump my mechanic alerted me about an advanced rusting deterioration on the structural frame of the car. Not only the body of the car is rusted but the fuel line pipes as well. The break fluid pipe broke two years ago due to rusting but fortunately I was able to stop the car by reducing gears. The rest of the car is in great condition (mechanically, electrically, etc) and it is a shame that in vital parts of the car Isuzu used cheap/non-resistant material. …”

   NHTSA complaint #10386130, filed 2011-03, 111,000 miles

   “The frame of my 1996 Isuzu Rodeo is completely rusted out. When searching online, I found that this is a very large issue that Isuzu is having. There are several other testimonials stating that their Isuzu Rodeo's frame is rusted away, and they have less then 100,000 miles on it. My Rodeo has 110,000 miles, but has probably been rusted out some time ago. There is absolutely no reason that a frame to any manufactured vehicle should be rusted out around 100,000 miles. …”

   NHTSA complaint #10416776, filed 2011-08
4. 4
   Brakes

   Rusty or soft brakes, ABS light on

   • 5 complaints (5%)
   • typically at 4.8 yrs old
   • filed 1996–2003

   Owners report rotors that rust and flake, a brake pedal that feels soft and can go to the floor, and ABS warning lights staying on while the vehicle is hard to stop. Several complaints note repeated dealer visits where the problem could not be reproduced, and one owner reported replacing rotors every couple of years. Reported at varied mileages, with several owners describing repeat failures over a few years of ownership.

   What to check: Check rotor surfaces for heavy pitting or flaking steel, and confirm the ABS light comes on at key-on and goes out. Ask for brake service records and have the pedal feel checked on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “Brakes: ABS brake light come on, when applying brakes they are soft and mushy. The last two occasions the brake pedal went completely to the floor. Vehicle was hard to stop. Been to dealership twelve times, and they cannot duplicate the malfunction.”

   NHTSA complaint #817894, filed 1998-01

   “When driving at 25 MPH consumer heard a knocking and ticking noise within the front end. Also, ABS light and the gas light did not work during long drives. Consumer has contacted the dealer. Please provide any further details.”

   NHTSA complaint #864823, filed 2000-07

Buying note. Look closely at the frame and the wheel studs before buying, since those are the two things owners raise most and both can be expensive or hard to fix. Ask for service records covering brakes and the air bag system, and budget for a thorough pre-purchase inspection on a lift.

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.