What is the 1995-2005 Chevrolet Blazer In-Tank Fuel Pump Premature Failure and Stalling?

Blazer in-tank fuel pumps fail well before normal service life — NHTSA complaints document failures from roughly 34,000 to 102,000 miles (averaging around 44,000 on the 2000 model year), often preceded by an erratic fuel gauge from the integrated sending unit corroding. GM produc… Repairs typically run $450-$900. Severity: high.

What is the 1995-2003 Chevrolet Blazer ABS False Activation at Low Speed from Wheel Speed Sensor Corrosion?

On 1995-2003 Blazer/S10 trucks, rust and debris build up on the front wheel speed sensor mounting surfaces, increasing the air gap between the sensor and the hub reluctor ring. The weakened signal makes the Kelsey-Hayes ABS falsely interpret a wheel as locking during light brakin… Repairs typically run $120-$600. Severity: high.

What is the 1996-2005 Chevrolet Blazer 4.3L V6 Lower Intake Manifold Gasket Coolant Leak?

The Vortec 4.3L V6 (like its 5.0L/5.7L siblings) used plastic-carrier lower intake manifold gaskets that erode and crack at the coolant ports from repeated thermal expansion cycles between the aluminum manifold and iron heads. Failures cluster between roughly 80,000 and 150,000 m… Repairs typically run $500-$1,100. Severity: high.

What is the 1995-1999 Chevrolet Blazer Lower Intake Manifold Gasket Coolant/Oil Leak?

The 4.3L Vortec rarely fails head gaskets but very commonly fails its lower (plenum) intake manifold gaskets. The original-equipment gaskets use plastic/composite carriers that harden and shrink with heat cycling, typically leaking between roughly 100k-150k miles. Left unaddresse… Repairs typically run $600-$1,000. Severity: high.

What is the 1995-1999 Chevrolet Blazer Front Lower Ball Joint Premature Wear / Failure (Non-Greaseable)?

The factory front lower ball joints on the S-series Blazer were sealed with no grease fittings and cannot be lubricated, leading to premature wear. NHTSA complaints document serious failures where the ball joint separates, the wheel folds under the vehicle, and steering control i… Repairs typically run $300-$800. Severity: high.

What is the 1995-1999 Chevrolet Blazer CSFI/CPI "Spider" Fuel Injector Assembly Failure (Poppet Valve Leaks)?

The 4.3L Vortec uses a Central Sequential Fuel Injection (CSFI, often called the "spider") assembly buried under the upper intake plenum, with individual nylon poppet lines feeding each cylinder. The poppet valves and the integrated fuel pressure regulator crack, stick, or leak w… Repairs typically run $300-$900. Severity: high.

What is the 1983-1997 Chevrolet Blazer Vacuum/Thermal Front Axle Actuator Failure — 4WD Won't Engage Front Wheels?

S-series 4x4s use a front axle disconnect operated by a vacuum-diaphragm actuator (or the notoriously slow thermal linear actuator on early-90s trucks) to couple the front axle after the transfer case shifts. The actuator diaphragm cracks and the small vacuum lines and switch ato… Repairs typically run $150-$500. Severity: medium.

What is the 1992-2005 Chevrolet Blazer Electric-Shift Transfer Case Encoder Motor and TCCM Failure (Service 4WD Light)?

Push-button 4WD Blazers use an electric encoder motor on the NP1 electronic-shift transfer case, commanded by the Transfer Case Control Module (TCCM). The encoder motor's internal position sensor and gears wear out, and TCCM faults are equally common, so the transfer case fails t… Repairs typically run $250-$700. Severity: medium.

What is the 1995-1999 Chevrolet Blazer Kelsey-Hayes ABS: Wheel Speed Sensor / EBCM Faults & Corroded Grounds?

The S-series Blazer's Kelsey-Hayes ABS system is prone to age-related faults: front wheel-speed sensors (integrated into the hub bearings) corrode and give erratic signals, the EBCM ground at the radiator support gets rusty/loose, and later Kelsey-Hayes 325 modules can fail inter… Repairs typically run $150-$600. Severity: medium.

What is the 1995-1999 Chevrolet Blazer NP8 Push-Button 4WD Transfer Case Encoder Motor / Selector Failure ("Service 4WD")?

4WD Blazers with the electric push-button New Process 233 transfer case (RPO NP8) use a TCCM-controlled encoder motor to shift ranges. The encoder motor, its position sensor, corroded selector-button contacts, and connector moisture are all common failure points, producing a "Ser… Repairs typically run $250-$700. Severity: medium.

What is the 1983-2005 Chevrolet Blazer Door Hinge Pin and Bushing Wear Causing Sagging Doors?

The heavy doors on two-door S-10 Blazers ride on small hinge pins with soft brass bushings that wear out — accelerated by lack of lubrication — letting the bushing holes in the hinge plates wallow out egg-shaped. The door then drops when opened, no longer aligns with the striker,… Repairs typically run $80-$300. Severity: low.

What is the 1995-1999 Chevrolet Blazer Instrument Cluster Gauge / Stepper Motor Failure?

The GM truck/SUV instrument clusters of this era use small air-core stepper motors to drive each gauge needle. Over time the internal dampening grease dries and the motors fail, causing needles to stick, read wildly wrong, or drop to zero. The speedometer and tachometer ("S" type… Repairs typically run $100-$400. Severity: low.

Chevrolet · Known Issues

1996 Chevrolet Blazer Problems: 13 Issues Every Owner Should Know

1996 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated July 2026

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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Chevrolet Blazer has 13 documented known issues, with 7 rated critical. The most serious are 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure ($500-$1,200 repair), In-Tank Fuel Pump Premature Failure and Stalling ($450-$900 repair), ABS False Activation at Low Speed from Wheel Speed Sensor Corrosion ($120-$600 repair), 4.3L V6 Lower Intake Manifold Gasket Coolant Leak ($500-$1,100 repair), Lower Intake Manifold Gasket Coolant/Oil Leak ($600-$1,000 repair), Front Lower Ball Joint Premature Wear / Failure (Non-Greaseable) ($300-$800 repair) and CSFI/CPI "Spider" Fuel Injector Assembly Failure (Poppet Valve Leaks) ($300-$900 repair). Across all issues with published estimates, repair costs range from $80 to $1,200. at .

Frequently Asked Questions

What are the most common Chevrolet Blazer problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Chevrolet Blazer has 13 documented issues. The most frequently reported are: 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure, In-Tank Fuel Pump Premature Failure and Stalling, ABS False Activation at Low Speed from Wheel Speed Sensor Corrosion. Of these, 7 are rated critical and should be addressed promptly.

Is the Chevrolet Blazer reliable?

The 1996 Chevrolet Blazer has 13 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 7 issues are rated critical: 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure and In-Tank Fuel Pump Premature Failure and Stalling and ABS False Activation at Low Speed from Wheel Speed Sensor Corrosion and 4.3L V6 Lower Intake Manifold Gasket Coolant Leak and Lower Intake Manifold Gasket Coolant/Oil Leak and Front Lower Ball Joint Premature Wear / Failure (Non-Greaseable) and CSFI/CPI "Spider" Fuel Injector Assembly Failure (Poppet Valve Leaks). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Chevrolet Blazer problems?

Repair costs for known Chevrolet Blazer issues range from $80 to $1,200, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure, typically costs $500-$1,200 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1992-2002 Chevrolet Blazer 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure?

The 4.3L Vortec V6 used a Central Port Injection system (CPI 1992-1995, CSFI 1996-2002) with a central injector body and six plastic poppet lines — the "spider" — mounted inside the intake manifold. The plastic lines and nut-kit connections crack and leak raw fuel into the plenum… Repairs typically run $500-$1,200. Severity: high.

All 13 Known Issues

Other Chevrolet Models

Frequently Asked Questions

What are the most common Chevrolet Blazer problems?

Is the Chevrolet Blazer reliable?

How much does it cost to fix common Chevrolet Blazer problems?

What is the 1992-2002 Chevrolet Blazer 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure?

1992-2002 Chevrolet Blazer: 4.3L V6 CPI/CSFI "Spider" Fuel Injector Leaks and Poppet Valve Failure#

1995-2005 Chevrolet Blazer: In-Tank Fuel Pump Premature Failure and Stalling#

1995-1999 Chevrolet Blazer: CSFI/CPI "Spider" Fuel Injector Assembly Failure (Poppet Valve Leaks)#

1995-2003 Chevrolet Blazer: ABS False Activation at Low Speed from Wheel Speed Sensor Corrosion#

1995-1999 Chevrolet Blazer: Kelsey-Hayes ABS: Wheel Speed Sensor / EBCM Faults & Corroded Grounds#

1996-2005 Chevrolet Blazer: 4.3L V6 Lower Intake Manifold Gasket Coolant Leak#

1995-1999 Chevrolet Blazer: Lower Intake Manifold Gasket Coolant/Oil Leak#

1995-1999 Chevrolet Blazer: Front Lower Ball Joint Premature Wear / Failure (Non-Greaseable)#

1983-1997 Chevrolet Blazer: Vacuum/Thermal Front Axle Actuator Failure — 4WD Won't Engage Front Wheels#

1992-2005 Chevrolet Blazer: Electric-Shift Transfer Case Encoder Motor and TCCM Failure (Service 4WD Light)#

1995-1999 Chevrolet Blazer: NP8 Push-Button 4WD Transfer Case Encoder Motor / Selector Failure ("Service 4WD")#

1983-2005 Chevrolet Blazer: Door Hinge Pin and Bushing Wear Causing Sagging Doors#

1995-1999 Chevrolet Blazer: Instrument Cluster Gauge / Stepper Motor Failure#