The 1996 Pontiac Sunfire has 7 NHTSA recall campaigns affecting an estimated 3,971,283 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 320 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
Recall campaigns
STEERING02V2860002002-11-041,159,156 affected
Defect
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
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…
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…
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
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…
SUSPENSION98V3190001998-12-1527,083 affected
Defect
VEHICLE DESCRIPTION: PASSENGER VEHICLES. ONE OF THE REAR SUSPENSION TRAILING ARM BOLTS CAN FATIGUE AND BREAK.
Consequence
IF THIS WERE TO OCCUR WHILE THE VEHICLE WAS IN MOTION, A LOSS OF VEHICLE CONTROL CAN OCCUR, INCREASING THE RISK OF A CRASH.
Remedy
DEALERS WILL REPLACE THE REAR SUSPENSION TRAILING ARM FASTENERS.
AIR BAGS98V1460001998-06-29675,302 affected
Defect
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
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
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
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
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.
Complaints by component
ENGINE AND ENGINE COOLING:ENGINE
21
AIR BAGS:FRONTAL
19
12crashes10injuries
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
15
7crashes6injuries
AIR BAGS
14
4crashes1fires5injuries
POWER TRAIN:AUTOMATIC TRANSMISSION
12
ELECTRICAL SYSTEM:IGNITION
9
2fires
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE
9
ELECTRICAL SYSTEM
8
2fires1injuries
ENGINE AND ENGINE COOLING:COOLING SYSTEM
8
STEERING:RACK AND PINION
8
Total complaints320
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Sunfire won't start a something with fuel pump”
“Sunfire won't start a something with fuel pump”
“Tl* the contact owns a 1996 pontiac sunfire. The contact stated that while parked, the driver's side air bag deployed inadvertently. The contact then shifted into reverse and the passenger's side air bag deployed inadvertently. The contact had not been involved in a crash. The vehicle was not…”
“Numerous failures with my car I am only listing the ones which have happened more than once 1..transmission failure, transmission failed 3 times first time while traveling 35mph car came to a dead stop tires locked up, car would not even roll, causing near accident. 2...window motors failed twice…”
“Numerous failures with my car I am only listing the ones which have happened more than once 1..transmission failure, transmission failed 3 times first time while traveling 35mph car came to a dead stop tires locked up, car would not even roll, causing near accident. 2...window motors failed twice…”
“Numerous failures with my car I am only listing the ones which have happened more than once 1..transmission failure, transmission failed 3 times first time while traveling 35mph car came to a dead stop tires locked up, car would not even roll, causing near accident. 2...window motors failed twice…”
“Numerous failures with my car I am only listing the ones which have happened more than once 1..transmission failure, transmission failed 3 times first time while traveling 35mph car came to a dead stop tires locked up, car would not even roll, causing near accident. 2...window motors failed twice…”
“Numerous failures with my car I am only listing the ones which have happened more than once 1..transmission failure, transmission failed 3 times first time while traveling 35mph car came to a dead stop tires locked up, car would not even roll, causing near accident. 2...window motors failed twice…”
Defect investigations
InvestigationDP03007 Opened 2003-10-14 · closed 2004-01-30
UNINTENDED VEHICLE ACCELERATION
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…
InvestigationEA98001 Opened 1998-01-23 · closed 1998-07-31
OVERSENSITIVE AIR BAG DEPLOYMENTS
There is no summary currently available
InvestigationPE02001 Opened 2002-01-03 · closed 2002-03-15
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1996 Pontiac Sunfire as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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