1996 Pontiac Sunfire problems

Defect

DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057, 7-3058, 7-3059 (SOLD UNDER THE "NAPA" BRAND NAME), AND PLATINUM PARTS #'S 2425151, 2425152, AND 2425153 MANUFACTURED DURING THE MONTH OF SEPTEMBER 2007. THESE REPLACEMENT STEERING SHAFTS CAN BE USED ON THE VEHICLES LISTED ABOVE. THE WELD CONNECTING THE INNER TUBE TO THE OUTER TUBE MAY BE DEFECTIVE.

Consequence

IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 16, 2008. OWNERS MAY CONTACT DORMAN TOLL FREE AT 1-800-523-2492.

Defect

CERTAIN DELPHI AFTERMARKET FUEL PUMP MODULES / MODULE RESERVOIR ASSEMBLIES (MRA) THAT WERE SOLD FOR USE ON THE ABOVE LISTED VEHICLES. DURING PRODUCTION THE MRAS VENT AND FUEL RETURN TUBES WERE REVERSED. THIS CONDITION CAN RESULT IN THE VEHICLE NOT RUNNING CORRECTLY (IDLE ROUGH AND/OR STALL) DUE TO AN OVERLY RICH FUEL BLEND OR THE VEHICLE'S EVAPORATIVE EMISSION CARBON CANISTER MAY LEAK FUEL.

Consequence

A STALLED VEHICLE CAN INCREASE THE RISK OF A VEHICLE CRASH. A FUEL LEAK CAN RESULT IN A FIRE.

Remedy

DELPHI WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE MRAS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2007. OWNERS CAN CONTACT DELPHI AT 1-877-335-7443.

Defect

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

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 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.

Defect

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 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.

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.

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.

Defect

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.

Defect

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.

Defect

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.