What is the 1995-2005 Chevrolet Cavalier 4T40-E Automatic Transmission Loses 3rd and 4th Gear / Loses Forward Gears?

The 4T40-E four-speed automatic behind the Cavalier's four-cylinder engines has two well-known internal failures. The first is a loss of third and fourth gear, addressed by GM in TSB 99-07-30-031 for 1999-2000 applications. The second is loss of all forward gears while reverse st… Repairs typically run $300-$2,800. Severity: high.

What is the 1996-1997 Chevrolet Cavalier Rear Suspension Trailing Arm Bolt Fatigues and Breaks (Recall 98V319)?

On J-body cars built roughly June 1996 through March 1997, one of the rear suspension trailing arm fasteners can fatigue and fracture. If the bolt breaks while the car is moving, the rear axle beam loses its locating point on that side and the driver can lose control. GM recalled… Repairs typically run $0-$300. Severity: high.

What is the 1995-2005 Chevrolet Cavalier Lower Intake Manifold Gasket Coolant Leak?

The 2.2L and 2.4L engines in the Cavalier are prone to intake manifold gasket failure, allowing coolant to leak externally or internally mix with oil. The composite gaskets deteriorate over time due to heat cycling. Dex-Cool coolant interaction with these gaskets accelerates dete… Repairs typically run $300-$600. Severity: medium.

What is the 1995-2005 Chevrolet Cavalier In-Tank Fuel Pump Module Failure - Whine Then Crank-No-Start?

The in-tank electric fuel pump module is a routine wear-out item on the 1995-2005 Cavalier and typically announces itself with a loud whine or high-pitched buzz from under the rear seat before it quits. When it fails the engine cranks normally with no sign of firing. Intermittent… Repairs typically run $250-$850. Severity: medium.

What is the 1995-2005 Chevrolet Cavalier Water Intrusion Into the Cabin - Rusted Cowl Corners, Blocked A/C Drain and Trunk Seals?

Soaked carpets are a signature J-body complaint and owners trace them to several specific places rather than one. The most damaging is rust perforating the far corners of the cowl panel under the wipers, which lets rainwater run straight down onto the front floor pan. Sunroof-equ… Repairs typically run $50-$800. Severity: medium.

What is the 1995-2005 Chevrolet Cavalier Rear Drum Brake Wheel Cylinder Leaks or Seizes - Soft Pedal or Dragging Rear Brakes?

Every Cavalier of this generation uses rear drum brakes with a cast wheel cylinder that corrodes internally, especially on cars in salt states and on cars whose brake fluid has never been flushed. Two outcomes are common: the cup seals let go and brake fluid soaks the shoes and t… Repairs typically run $150-$450. Severity: medium.

What is the 1995-2005 Chevrolet Cavalier Blower Motor Resistor Burns Out - Heater Fan Works Only on High?

The Cavalier's HVAC blower speeds below high are routed through a resistor pack mounted in the heater case in the passenger footwell. High speed bypasses the resistor entirely on its own relay-fed circuit, so when the resistor's coils burn open the fan works only on the highest s… Repairs typically run $15-$180. Severity: low.

Chevrolet · Known Issues

1996 Chevrolet Cavalier Problems: 12 Known Issues

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

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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Chevrolet Cavalier has 12 documented known issues, with 7 rated critical. The most serious are 2.2L/2.4L Head Gasket Failure ($800-$1,800 repair), Ignition Switch Contact Failure ($150-$500 repair), Power Steering Rack Lower Pinion Bearing Separates, Causing Sudden Steering Effort Change (Recall 02V286) ($0-$900 repair), 2.4L LD9 Twin Cam (Z24) Timing Chain Guide and Tensioner Wear - Chain Slack and Jumped Timing ($600-$2,000 repair), 4T40-E Automatic Transmission Loses 3rd and 4th Gear / Loses Forward Gears ($300-$2,800 repair), Rear Suspension Trailing Arm Bolt Fatigues and Breaks (Recall 98V319) ($0-$300 repair) and Ignition Switch Overheats and Melts, Causing Steering Column Fire (Recalls 02V070 / 04V036) ($0-$250 repair). Across all issues with published estimates, repair costs range from $15 to $2,800.

Frequently Asked Questions

What are the most common Chevrolet Cavalier problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1996 Chevrolet Cavalier has 12 documented issues. The most frequently reported are: 2.2L/2.4L Head Gasket Failure, Ignition Switch Contact Failure, Power Steering Rack Lower Pinion Bearing Separates, Causing Sudden Steering Effort Change (Recall 02V286). Of these, 7 are rated critical and should be addressed promptly.

Is the Chevrolet Cavalier reliable?

The 1996 Chevrolet Cavalier has 12 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 7 issues are rated critical: 2.2L/2.4L Head Gasket Failure and Ignition Switch Contact Failure and Power Steering Rack Lower Pinion Bearing Separates, Causing Sudden Steering Effort Change (Recall 02V286) and 2.4L LD9 Twin Cam (Z24) Timing Chain Guide and Tensioner Wear - Chain Slack and Jumped Timing and 4T40-E Automatic Transmission Loses 3rd and 4th Gear / Loses Forward Gears and Rear Suspension Trailing Arm Bolt Fatigues and Breaks (Recall 98V319) and Ignition Switch Overheats and Melts, Causing Steering Column Fire (Recalls 02V070 / 04V036). 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 Cavalier problems?

Repair costs for known Chevrolet Cavalier issues range from $0 to $2,800, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 2.2L/2.4L Head Gasket Failure, typically costs $800-$1,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1995-2005 Chevrolet Cavalier 2.2L/2.4L Head Gasket Failure?

Both the 2.2L OHV and 2.4L Twin Cam engines in the Cavalier are prone to head gasket failure. The 2.4L is particularly susceptible due to the aluminum head and iron block thermal expansion differences. Repairs typically run $800-$1,800. Severity: high.

All 12 Known Issues

Other Chevrolet Models

Frequently Asked Questions

What are the most common Chevrolet Cavalier problems?

Is the Chevrolet Cavalier reliable?

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

What is the 1995-2005 Chevrolet Cavalier 2.2L/2.4L Head Gasket Failure?

What is the 1995-2005 Chevrolet Cavalier Ignition Switch Contact Failure?

1995-2005 Chevrolet Cavalier: 2.2L/2.4L Head Gasket Failure#

1996-2002 Chevrolet Cavalier: 2.4L LD9 Twin Cam (Z24) Timing Chain Guide and Tensioner Wear - Chain Slack and Jumped Timing#

1995-2005 Chevrolet Cavalier: Lower Intake Manifold Gasket Coolant Leak#

1995-2005 Chevrolet Cavalier: Ignition Switch Contact Failure#

1995-2001 Chevrolet Cavalier: Ignition Switch Overheats and Melts, Causing Steering Column Fire (Recalls 02V070 / 04V036)#

1996-1997 Chevrolet Cavalier: Power Steering Rack Lower Pinion Bearing Separates, Causing Sudden Steering Effort Change (Recall 02V286)#

1995-2005 Chevrolet Cavalier: 4T40-E Automatic Transmission Loses 3rd and 4th Gear / Loses Forward Gears#

1996-1997 Chevrolet Cavalier: Rear Suspension Trailing Arm Bolt Fatigues and Breaks (Recall 98V319)#

1995-2005 Chevrolet Cavalier: In-Tank Fuel Pump Module Failure - Whine Then Crank-No-Start#

1995-2005 Chevrolet Cavalier: Water Intrusion Into the Cabin - Rusted Cowl Corners, Blocked A/C Drain and Trunk Seals#

1995-2005 Chevrolet Cavalier: Rear Drum Brake Wheel Cylinder Leaks or Seizes - Soft Pedal or Dragging Rear Brakes#

1995-2005 Chevrolet Cavalier: Blower Motor Resistor Burns Out - Heater Fan Works Only on High#

What is the 1996-1997 Chevrolet Cavalier Power Steering Rack Lower Pinion Bearing Separates, Causing Sudden Steering Effort Change (Recall 02V286)?

What is the 1996-2002 Chevrolet Cavalier 2.4L LD9 Twin Cam (Z24) Timing Chain Guide and Tensioner Wear - Chain Slack and Jumped Timing?