Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Chevrolet Cavalier owners, lightly cleaned up (personal details are redacted by NHTSA).
The consumer turned on the engine and noticed smoke coming through the ignition switch, two minutes later, the steering wheel was on fire. Dealer notified. Consumer indicated there was a NHTSA recall on this issue.
Head gasket on my 1996 Chevrolet Cavalier. We couldn't figure out why the vehicle would continue to stall , after placing nearly $800.00 worth of new parts in vehicle, changing several alternators and starters, from the ingnition swith recall. I had taken to a mechanic and found out the car had a blown head gasket. Which, apparently there is a recall on other cavaliers, although not with my VIN number. I have called GM motors and they want me to have the car diagnosised at their dealership, costing $100-$200. And now having to spend $400-$600 on another defect from these recalls, is really frustrating my family, espically my husband. We don't have the extra money to keep placing in this vechile, I'm a full time student with a 2 year old son and work only part time. I need a reliable car. I can't spend more money at the dealership and not have a guarentee that they wouldn' fix this part. …
Driving down the road, motor stops running and I lost all power both steering and electrical. Got it to the side of the road. Waited 2 minutes and started it back up it was fine. Only did this 2 times within a week period. Engine idle rough since I purchased it in 1998. Took it in and they said they could not find anything. Came back several times they essentially said thay could do nothing thats just how they run. Motor surges and lags after start up. Regardless of temperature. Push pedal motor bogs down and then it will take off. Replaced almost every sensor under the hood problem is still present. Battery took a dump at almost 4 years. Engine spun #3 and #4 bearings on a cold start up. They advised me that I needed a water pump at the same time.pass power window was always slow. Replaced approx mid 2002 rear suspension clunks and sounds like it has lumber in the trunk. …
Dt: the consumer stated he bought a car on 6-29-05 from klick lewis inc. On his way home when he applied the brakes, suddenly the car felt like it was coming apart. He called the dealer where he bought the car and they told him the vehicle needed front rotors. On Friday 7-15-05; before he had taken it in to have the rotors put on, he noticed the car was full of smoke. He called the fire dept. And they came out and diffused the fire and told him that it was an electrical problem and the car could have caught on fire. He then called the salesperson that sold him the car and they said they would have someone get back to him. He has made 5 telephone calls to them and no one has returned his calls.
The horn does not always work. It has contribute to two different accidents. The first was when my car backed into another Cavalier, same year, and she informed me that her horn would not honk. The second was when a car backed into me and I tried several times tohonk the horn to worn the man he was about to hit me and the horn would not work. This has caused two different accidents just in my case. The horn works occasionally, but it doesn't work more often than it does. This could really be a hazard.
This car shuts off while driving like the GM cars being mentioned in the news today. Started in 2005 and was evaluated by multiple mechanics including a Chevrolet dealership that kept it over a month. It doesn't show a code when it happens. It randomly shuts off while you are driving (varied speeds). It also randomly won't start. Totally unpredictable when it will quit on you or not start.resetting did not help.car was purchased for daughter (new driver) to drive, but was too unsafe.
Having problems with stalling, placed other complaints recently. Steering locking up and fixed more part in vechile, now might be relating to the ignition switch recall, which my mechanic has found was inproperlly placed in car. Called the dealership and since it has been over 1 year and 12,000 miles, they will charge me a labor fee and also the part fee. Could this become any worse GM??????
Fuel pump seal disintegrated. Cost $1,081.00 (including 3 day car rental). Earlier this year there was a recall on the steering column and I wound up paying an additional $600 for other defects not covered by the recall. Think that this and many additional problems on this car constitute it being a lemon. More than 5 recalls in 7 years.
Prior to recall notification (02V070000) consumers vehicle experienced the same failure, consumer was informed by the dealership that a refund would be in order, however consumer still had not received any compensation, consumer was then informed that the reimbusement was denied stating that the recall was not covered.
Vehicle was sitting all day until the evening when consuemr went out and inside of the vehicle was filled with smoke. Consumer found out that wiriing harness under dash caught on fire. Manufacturer was not concerned with incident, but interested to know what consumer was seeking.
Related recalls
Electrical system › Ignition › Switch
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.
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.
NHTSA investigations
Fire in steering column area
Electrical complaints in other Cavalier years
Frequently asked questions
How common are electrical problems on the 1996 Chevrolet Cavalier?
NHTSA has 100 complaints about the electrical system of the 1996 Chevrolet Cavalier, 20% of the model year's 503 complaints. The component named most often is horn (24 mentions).
Is there a recall for 1996 Chevrolet Cavalier electrical problems?
Yes — NHTSA recall 02V-070 (switch, Mar 6, 2002). Recall repairs are free at authorized dealers.
At what mileage do 1996 Chevrolet Cavalier electrical problems start?
Half of the complaints with a recorded mileage happened before about 61,000 miles, and 23% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 9 fires and 0 injuries and 1 death to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.