What is the 1996-2000 Chevrolet Tahoe CSFI 'Spider' Central Port Injector / Poppet Valve Failure (5.7L Vortec)?

The 1996-2000 5.7L Vortec (L31) uses a Central Sequential Fuel Injection (CSFI) 'spider' assembly: one central housing feeds six nylon poppet spray nozzles via tubes. The poppet valves gum up with carbon and either stick open (raw fuel dumps, rich condition, hard hot/cold startin… Repairs typically run $400-$900. Severity: high.

What is the 1995-1999 Chevrolet Tahoe In-tank fuel pump failure and pigtail connector meltdown?

The in-tank electric fuel pump on the GMT400 Tahoe is a common wear-out item, often failing around/after 100,000 miles. Continuous-duty operation, chronic low-fuel driving (which reduces pump cooling), and tank sediment clogging the sock filter all shorten pump life. A frequently… Repairs typically run $400-$850. Severity: high.

What is the 1995-2010 Chevrolet Tahoe 4L60E Automatic Transmission 3-4 Clutch Failure (Loss of 3rd/4th Gear)?

The 4L60E 4-speed automatic behind the Vortec V8s is the single most common major failure on high-mileage Tahoes. The 3-4 clutch pack is the known weak point: its friction plates burn up, and the truck suddenly slips or drops out of 3rd and 4th gear (RPMs flare with no accelerati… Repairs typically run $1,800-$3,500. Severity: high.

What is the 1995-1999 Chevrolet Tahoe Brake line and fuel line rust-through corrosion (Salt Belt)?

The steel brake and fuel lines on GMT400 Tahoes corrode and rupture, especially in road-salt states. Brake lines rust from the outside in and can burst suddenly, producing a sinking pedal and severe loss of stopping power, frequently with no warning light. NHTSA received ~890 bra… Repairs typically run $600-$1,600. Severity: high.

What is the 1996-1999 Chevrolet Tahoe CSFI "spider" poppet fuel injector failure (special coverage 99066F)?

The 5.7L, 5.0L and 4.3L Vortec engines used a Central Sequential Fuel Injection (CSFI) "spider" assembly with nylon fuel tubes ending in spring-loaded poppet nozzles inside the intake. The poppets clog with carbon or leak/stick open, causing raw fuel intrusion, hard starting/floo… Repairs typically run $500-$1,100. Severity: high.

What is the 1996-1999 Chevrolet Tahoe Lower intake manifold gasket coolant/vacuum leak (5.7L Vortec)?

The 1996-1999 5.7L Vortec (L31) and 5.0L Vortec (L30) used a plastic-carrier composite lower intake manifold gasket that degrades and fails, typically between 60,000-120,000 miles. Failures commonly occur at the coolant ports and near the valley/distributor area, letting coolant… Repairs typically run $400-$900. Severity: high.

What is the 1996-1999 Chevrolet Tahoe Distributor cap and rotor moisture corrosion (frequent replacement)?

The 1996-1999 Vortec's distributor sits nearly vertical, and its ventilation design allows moisture and condensation to accumulate inside the cap. This causes corrosion, carbon tracking, and cracking of the cap and rotor, producing intermittent misfires and stalling, especially i… Repairs typically run $60-$250. Severity: medium.

What is the 1996-2007 Chevrolet Tahoe Lower Intake Manifold Gasket Coolant Leak (Dex-Cool Erosion)?

Vortec V8 Tahoes are well known for lower intake manifold gasket leaks, most often at the driver-side rear corner coolant passages. Dex-Cool (orange) coolant is hard on these gaskets, softening/distorting them and eroding the aluminum sealing surface, allowing coolant to weep ext… Repairs typically run $700-$1,100. Severity: medium.

Chevrolet · Known Issues

1997 Chevrolet Tahoe Problems: 9 Known Issues

1997 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 1997 Chevrolet Tahoe has 9 documented known issues, with 7 rated critical. The most serious are 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches) ($1,500-$2,800 repair), CSFI 'Spider' Central Port Injector / Poppet Valve Failure (5.7L Vortec) ($400-$900 repair), In-tank fuel pump failure and pigtail connector meltdown ($400-$850 repair), 4L60E Automatic Transmission 3-4 Clutch Failure (Loss of 3rd/4th Gear) ($1,800-$3,500 repair), Brake line and fuel line rust-through corrosion (Salt Belt) ($600-$1,600 repair), CSFI "spider" poppet fuel injector failure (special coverage 99066F) ($500-$1,100 repair) and Lower intake manifold gasket coolant/vacuum leak (5.7L Vortec) ($400-$900 repair). Across all issues with published estimates, repair costs range from $60 to $3,500. DIY maintenance guides at .

Frequently Asked Questions

What are the most common Chevrolet Tahoe problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1997 Chevrolet Tahoe has 9 documented issues. The most frequently reported are: 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches), CSFI 'Spider' Central Port Injector / Poppet Valve Failure (5.7L Vortec), In-tank fuel pump failure and pigtail connector meltdown. Of these, 7 are rated critical and should be addressed promptly.

Is the Chevrolet Tahoe reliable?

The 1997 Chevrolet Tahoe has 9 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 7 issues are rated critical: 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches) and CSFI 'Spider' Central Port Injector / Poppet Valve Failure (5.7L Vortec) and In-tank fuel pump failure and pigtail connector meltdown and 4L60E Automatic Transmission 3-4 Clutch Failure (Loss of 3rd/4th Gear) and Brake line and fuel line rust-through corrosion (Salt Belt) and CSFI "spider" poppet fuel injector failure (special coverage 99066F) and Lower intake manifold gasket coolant/vacuum leak (5.7L Vortec). 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 Tahoe problems?

Repair costs for known Chevrolet Tahoe issues range from $60 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches), typically costs $1,500-$2,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1995-1999 Chevrolet Tahoe 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches)?

The 4L60E automatic behind the 5.7L is prone to losing reverse (and sometimes 2nd) as it ages. The classic root cause is the reaction sun shell ("sunshell") cracking or stripping its splines, along with worn lo-reverse clutches. Slipping typically appears first in reverse and wor… Repairs typically run $1,500-$2,800. Severity: high.

All 9 Known Issues

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Frequently Asked Questions

What are the most common Chevrolet Tahoe problems?

Is the Chevrolet Tahoe reliable?

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

What is the 1995-1999 Chevrolet Tahoe 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches)?

1996-2000 Chevrolet Tahoe: CSFI 'Spider' Central Port Injector / Poppet Valve Failure (5.7L Vortec)#

1995-1999 Chevrolet Tahoe: In-tank fuel pump failure and pigtail connector meltdown#

1996-1999 Chevrolet Tahoe: CSFI "spider" poppet fuel injector failure (special coverage 99066F)#

1995-1999 Chevrolet Tahoe: 4L60E transmission loss of reverse (cracked sun shell / worn lo-reverse clutches)#

1995-2010 Chevrolet Tahoe: 4L60E Automatic Transmission 3-4 Clutch Failure (Loss of 3rd/4th Gear)#

1996-1999 Chevrolet Tahoe: Lower intake manifold gasket coolant/vacuum leak (5.7L Vortec)#

1996-2007 Chevrolet Tahoe: Lower Intake Manifold Gasket Coolant Leak (Dex-Cool Erosion)#

1995-1999 Chevrolet Tahoe: Brake line and fuel line rust-through corrosion (Salt Belt)#

1996-1999 Chevrolet Tahoe: Distributor cap and rotor moisture corrosion (frequent replacement)#