1996 Chevrolet Suburban Electrical System

THE BATTERY CABLES LEAK ACID, . WHEN THE BATTERY BECOMES CORRODED, THERE IS NO POWER TO THE VEHICLE. THE DEALER HAS TOLD ME THAT THE BATTERY CABLES ARE BAD, WHICH WE HAVE REPLACED, AND THE PROBLEM CONTINUES. WE HAVE HAD THE BATTERIES (REPLACED MORE THAN ONE) CHECKED, AND THEY ARE FINE. WE HAVE HAD THE POSTS REPLACED, AND THE PROBLEM GETS WORSE. THE LATEST, (IM STRANDED RIGHT NOW) SEEMS TO BE THE WORST YET. AT FIRST WHEN THIS STARTED HAPPENING, IT WAS A COUPLE OF MONTHS APART, NOW ITS EVERY WEEK. ALSO WHEN IT STARTED THE CABLES WHERE REALLY CORRODED BEFORE THE ENGINE QUIT. NOW THEY CAN BE WIPED OFF WITH A DRY TOWEL. ALSO, THE A/C HAS STOPPED WORKING DUE TO CRACKS IN HOSES. (FROM THE ACID) BEING AS I LIVE IN TEXAS, EVEN IF THE TRUCK IS RUNNING I CANT DRIVE IT IN THE SUMMER, EVEN IF WE FIX THE HOSES IT HAPPENS AGAIN. WHEN I HAD THE VEHICLE TOWED TO THE DEALER THE LAST TIME, THEY TOLD ME THE BATTERY WAS FINE, BUT I NEEDED TO SPEND 400.00 TO HAVE THE CABLES REPLACED AGAIN. HOW IS THIS PROBLEM REALLY CORRECTED. TALKING TO OTHER PEOPLE WHO HAD SUBURBANS I HAVE FOUND THAT A NUMBER OF THEM HAVE HAD VEHICLE FIRES DUE TO THE ACID PROBLEM!!! HAVING CHILDREN IN THE CAR, IM TERRIFIED TO DRIVE MY TRUCK. (WHEN IT EVEN STARTS) I CANNOT SELL IT TO SOMEONE ELSE AND PUT THEM IN DANGER. THE FUEL PUMP HAS FAILED. WE WERE TOLD THAT WE HAVE TO KEEP A 1/4 TANK OF GAS IN THE TRUCK. WELL IT IS GOING OUT AGAIN AND I KEEP IT FULL! ALSO, SOMETHING TO DO W/ THE ABS BOOSTER BEING BAD. WELL MY BRAKES ARE FAILING AGAIN. (LESS THAN A YEAR LATER) THE PADS ARE FINE. THE ACID LEAKING HAS CAUSED DAMAGE TO OUR DRIVEWAYS, NOT TO MENTION THE KIDS AND ANIMALS IN THE NEIGHBORHOOD GETTING INTO THE ACID ON THE GROUND. PLEASE SEND ME ANY INFO THAT MIGHT HELP ME. IM AM GOING TO CONTACT THE DEALER AND TALK TO THEM AGAIN ABOUT THE INFORMATION THE I HAVE FOUND, RE: IM NOT THE ONLY ONE THIS IS HAPPENING TO. *NM

1996 CHEVROLET SUBURBAN, SIDE MIRROR REMOTE CONTROL IN DRIVERS DOOR PANEL CAUGHT ON FIRE. I TORE OUT THE PANEL AND CUT THE WIRES TO REMOVE IT BEFORE THE TRUCK CAUGHT COMPLETELY ON FIRE. *JB

CONSUMER STATED THAT WHILE DRIVING VEHICLE CUT OFF. CONSUMER TOOK VEHICLE TO A CHEVROLET DEALER/MECHANIC, AND EACH TIME WAS TOLD THAT VEHICLE NEEDED NEW BATTERY CABLES. THE BATTERY CABLES WERE REPLACED TWICE, BUT VEHICLE KEPT DOING THE SAME THING. *AK

PROBLEM: ENGINE SHUTS OFF AT ANY SPEED. WILL RESTART. AFTER NUMEROUS VISITS TO DEALER BETWEEN APRIL 99 AND JAN 2000 AND FUEL PUMP REPLACED 3 TIMES AND PROBLEM CONTINUED. PROBLEM WOULD OCCUR ON INTERSTATE AT HIGH SPEED, OR IN THE MIDDLE OF AN INTERSECTION DURING ACCELERATION, OR WHILE IDLING. LOSS OF CONTROL A PROBLEM ON WINDING ROADS OR WHILE ENGAGING AN INTERSECTION. DEALER FINALLY REPLACED ECM (COMPUTER) IN JAN/FEB 2000 AFTER A LETTER TO DEALERSHIP PROBLEM CORRECTED. MFG. EXTENDED WARRANTY TO 120,000 MI. ENGINE SHUT OFF AND WOULD NOT RESTART IN MARCH 2002 REAR TRANSFER PUMP REPLACED. IN NOV. 2002, ENGINE HAS BEGUN TO SHUT OFF AGAIN (AT LEAST 5 TIMES) SINCE 11/20. I ANTICIPATE A LARGE BILL FROM DEALER TO CORRECT A RECURRING PROBLEM. WILL TAKE TO DEALER THIS WEEK (12/2/2002). DT

VEHICLE CAUGHT ON FIRE ON DRIVER'S SIDE DOOR DUE TO AN ELECTRICAL SHORT IN WIRING. VEHICLE WAS TOTALED. MANUFACTURER HAS BEEN NOTIFIED. PLEASE PROVIDE ADDITIONAL INFORMATION.*AK

CONSUMER WAS TRAVELING ABOUT 60 MPH ON MAJOR HIGHWAY AND VEHICLE JUST SHUT OFF WITHOUT PRIOR NOTICE WHILE PULLING A TRAILER. THERE WERE NO INJURIES. *AK

UPON EXITING FREEWAY I NOTICED A BURNING ODOR. PARKED THE SURBURBAN AND LIFTED THE HOOD AND DISCOVERED THE LEFT FRONT AREA OF ENGINE ON FIRE. I EXTINGUISHED THE FLAME AND THE RESULTING DAMAGE EXHIBITED SPARK PLUG WIRES 1 AND 3 TOTALLY BURNT TO ASH. WIRE HARNESS TO AIR CONDITIONING AND ENGINE TEMPERATURE SENSOR INSULATION WAS BURNT AWAY. OIL FILLER NECK IS COMPLETLY MELTED AWAY AS ARE THE SPARKPLUG WIRE MOUNTING BRACKETS. PLASTIC VACCUUM HOSE FOR EMMISSION DEVICE WAS ALSO MELTED IN HALF. UPPER RADIATOR HOSE IS BADLY BURNT. SUSPECT ELECTRICAL WIRE HARNESS PROBLEM WITH VEHICLE SINCE THE BATTERY SPLIT OPEN 1 YEAR PRIOR SPILLING ACID ALL OVER BRAKE LINES AND AIR CONDITIONER PLUMBING. *AK

DEALER REFUSED TO WARRANT THE CABLE, ALTHOUGH THE EXTENDED WARRANTY CLEARLY INDICATES THAT IT WAS COVERED.*AK

DROVE VEHICLE & MADE A STOP. RETURNED TO VEHICLE WITH CHILDREN & STARTED VEHICLE. NOTICED SMOKE COMING FROM UNDER THE HOOD. RETRIEVED CHILDREN OUT OF VEHICLE & LEFT. VEHICLE EXPLODED. FIRE DEPT. ARRIVED TO PUT FLAMES OUT. GAVE NO INDICATION OF CAUSE OF FIRE. *AK

BATTERY LEAKS AND SUBSEQUENT POSITIVE CONNECTOR/CABLES ROTTENING FROM ACID PREVENT CURRENT FLOW TO THE STARTER AND TO THE COMPUTER - SO THAT THE ENGINE WILL NOT START. IT IS NECESSARY TO LOOSEN THE BATTERY CABLES, AND CLEAN SOAK THEM IN A MIXTURE OF SODA AND WATER, THEN REHOOK! MY WIFE CAN NO LONGER USE THE CAR, BECAUSE SHE IS UNABLE MAKE REPAIRS OF THIS NATURE, IN THE VERY GOOD LIKELIHOOD THAT THE FAILURE TO CRANK WILL OCCUR WHEN SHE IS DRIVING. I HAVE PREVIOUSLY REPORTED THIS, BUT DID NOT REPORT THAT I HAVE JUST DISCOVERED THAT BATTERY ACID LEAKS HAVE CAUSED SEVERE RUSTING OF THE RIGHT FRONT BRAKE TUBING DIRECTLY UNDER THE BATTERY CONNECTIONS. THIS PRESENTS A POTENTIALLY SERIOUS SAFETY MATTER. FYI, THE CAR NOW HAS HAD 3 DELCO 78 SERIES BATTERY IN IT - FIRST TWO REPLACED BECAUSE OF LEAKING!! , AND NOW THE NEW 3RD ONE IS LEAKING. WILLIAM J FISHER. *AK

DELCO BATTERY WAS CRACKED CAUSING ACID TO LEAK DOWN THE WIRING TO THE FRAME. NLM

BATTERY FAILURE RESULTING IN POSITIVE TERMINAL PULLING OUT OF BATTERY AND ACID SPILLING ON AIR CONDITIONING AND BRAKE LINES. REPLACED BATERY AND CONNECTIONS CAME LOOSE AND TRUCK SHUTDOWN COMPLETELY. THIS HAS HAPPENED ON THREE OCCASIONS. THE TERMINALS HAVE BEEN CLEANED EACH TIME AND TRUCK WILL RUN FINE. INITIAL FAILURE RESULTED IN BATERY ACID SPILLING ON INNER FENDER AND BRAKE LINES. PROBLEM WAS FOUND BEFORE ACID ATE THROUGH BRAKE LINES AND AIR CONDITIONING LINES. DURING OTHER FAILURES BATTERY TERMINAL HAS NOT PULLED OUT OF BATERRY BUT POSITIVE TERMINALS HAVE HAD CORROSIVE BUILD UP CAUSING TRUCK TO SHUT DOWN COMPLETLY. AFTER PULLING CONNECTIONS LOOSE AND CLEANING THEN TRUCK FUNCTIONS FINE FOR A FEW MONTHS THEN IT WILL HAPPEN AGAIN. THIS POSES A SERIUOS CONDITION DUE TO LACK OF WARNING .*AK

ACID LEAKAGES FROM DELCO BATTERY POST. THIS WAS THE THIRD TIME THAT THIS PROBLEM OCCURRED. FEEL FREE TO PROVIDE FURTHER DETAILS. *AK

NO SUMMARY LISTED FOR ABOVE VEHICLE. *AK

THE ORIGINAL BATTERY LEAKED AND CAUSED A POWER OUTAGE,CAUSING THE POSITIVE CABLES TO EVENTUALLY START CORRODING INTERNALLY.THE DEALER REPLACED THE DEFECTIVE BATTERY UNDER WARRANTY.SEVERAL MONTHS LATER THE REPLACED BATTERY CAUSED THE SAME PROBLEM,BUT THIS TIME IT INTERNALLY CORRODE THE POSITIVE CABLES.I WENT TO THE DEALERSHIP AND EXPLAINED TO THEM THAT THE BATTERY LEAKED AGAIN AND CORRODED THE POSITIVE CABLES.THEY REFUSED TO REPLACE THE BATTERY.SO I HAD TO BUY A NEW BATTERY AND BOUGHT A NEW PAIR OF POSITIVE CABLES AND INSTALLED THEM MYSELF.I FILED A COMPLAINT WITH GM AND THEY DID NOT DO ANYTHING ABOUT IT.I CONTACTED AC DELCO TO TELL THEM THAT I FELT THAT THEY HAD A BATTERY PROBLEM AND THEY NEVER CONTACTED ME BACK.

FIRST TIME AT 30,000 MILES, SYMPTOMS APPEARED TO BE DEFECTIVE STARTER OR STARTED SOLENOID- FOUND THAT THE BATTERY WAS LEAKING AT THE POSITIVE TERMINAL AND CORRODED/RUINED CABLE CONNECTING TO BATTERY. DEALER IN NORTH CAROLINA [PARKS CHEVROLET, CHARLOTTE REPLACE BATTERY AND CABLES, FREE]. SECOND TIME, AT 50,000 MILES, I CHECKED BATTERY AND FOUND LEAKING AGAIN - SOAKED CABLE CONNECTIONS IN BAKING SODA WATER SOLUTION AND RE-INSTALLED WITH NEW BOLT. SINCE THAT TIME, I HAVE CLEANED THE CABLE CONNECTION AT BATTERY POSITIVE POST WITH SODA/WATER SOLUTION AT APPROXIMNATELY 10,000 MILE INTERVALS. FROM TALKING TO OTHER OWNERS, IT APPEARS THAT THE BATTERIES ARE THE PROBLEM - LEAKING AT THE POSITIVE BOLT/TERMINAL CONNECTION. AS A FORMER MECHANIC AND FACTORY SERVICE REP, I HAVE BEEN ABLE TO AVOID A SERIOUS THREAT TO SAFETY BY FREQUENT INSPECTION AND MAINTENANCE, BUT THIS IS REALLY A DANGEROUS SITUATION AND MAY HAVE FRIGHTENING RESULTS UNLESS SOME ACTION IS TAKEN TO CORRECT

NO SUMMARY LISTED FOR ABOV EVEHICLE. *AK

AC DELCO BATTERY IS LEAKING ACID. DUE TO A SPILLAGE, ACID HAS EATEN THROUGH RIGHT WHEEL BRAKING SENSOR. *AK

BATTERY LEKAED ACID ONTO THE BRAKES, RESULTING IN BRAKE FAILURE. VEHICLE HAS BEEN REPAIRED. DEALER WAS NOTIFIED. *AK

THE MOST BE SOME PROBLEM WITH ELECTRICAL PARTS, ITS BEEN HAPPENIG SINCE NEW

DELCO BATTERY CASE CRACKED AND LEAKED ACID. ORIGINAL BATTERY AND REPLACEMENT BOTH FAILED IN SIMILAR FASHION. PROBLEM WAS REPORTED EARLIER AND I WAS CONTACTED BY NHTSA INVESTIGATOR. HE ASKED IF THERE HAD BEEN ANY CORROSION OF BRAKE LINES OR AIR BAG WIRING. I DID NOT KNOW. HAVE NOW CHECKED AND FOUND CORROSION ON A BRAKE LINE AND AIR BAG WIRING WHICH RUNS DIRECTLY UNDER BATTERY TRAY.

ORIGINAL BATTERY (DELCO) CRACKED AND SPILLED BATTERY ACID ON HOSES AND WIRING. REPLACEMENT BATTERY (DELCO) FAILED IN SIMILAR FASHION AFTER 65,000 MILES.

THE BATTERY HAS BEEN REPLACED 3 TIMES WITHIN THE LAST THREE YEARS, EACH TIME WITH A NEW BATTERY. THREE WEEKS AGO, A NEW BATTERY WAS PUT IN THE TRUCK AGAIN. ALSO, ALTERNATOR IS NOT BIG ENOUGH FOR THIS TRUCK, WHICH KILLS THE BATTERY. THE DEALER HAS NOT BEEN NOTIFIED ABOUT THIS PROBLEM. PLEASE PROVIDE ANY FURTHER INFORMATION. *AK

THE ALTERNATOR HAD BURNED OUT. BATTERY WAS NOT CHARGING. VEHICLE DID NOT START. HAD ALTERNATOR REPLACED TWICE. WAS TOLD ALTERNATOR WAS NOT STRONG ENOUGH FOR VEHICLE. *AK

VEHICLE WOULD NOT START OF SEVERAL OCCASIONS. ALTERNATOR SHORTED AND CAUSED A FIRE WHILE VEHICLE WAS PARKED AND ENGINE OFF. REPAIRED BY DEALER. STILL HAS EPISODES OF NOT STARTING. DEALER CANNOT FIND PROBLEM.