Summary
The Pontiac Bonneville has 24 recalls spanning 1975 through 2003, with the most serious recent issue affecting 2003 SSEI models where a faulty fuel tank pressure sensor can cause fuel to leak during refueling, creating a fire risk near any ignition source.
The 2003 model year also has a driver's side airbag inflator that can fracture at a weld during deployment, sending fragments into the cabin while leaving the bag unable to fully protect the driver. On 2002 SSEI models, the same fuel tank pressure sensor defect can apply excessive vacuum during self-diagnostic testing, damaging fuel system components and causing leaks.
The 2000 model year has two concerns: a fuel pressure regulator on 3800 V6 (L36) engines that can leak fuel into the intake manifold, and if the engine fails to start, a backfire can rupture the manifold, pull an injector loose, and cause a fuel fire. Separately, some 2000 vehicles have internal fluid leaks in the brake hydraulic control unit that can prevent the anti-lock brakes, traction control, or stability control from activating properly in situations where those systems would normally intervene.
The 1999 model year has chrome-plated aluminum wheels that can have an improperly machined mounting surface, causing wheel studs to break and the tire and wheel assembly to separate from the vehicle while in motion. There is also a transmission shift cable issue on 1999 models with 4T65E automatic transmissions where the cable can disconnect, causing the gear indicator to show a different position than where the transmission actually is.
On 1997 models, seat cover trim material does not meet flammability standards and can ignite more readily than required if an ignition source is present. The 1995 model year has a lighting control module that can leak current through damaged capacitors, causing the headlamps and parking lamps to go out without warning.
The 1993 model year has a transmission oil cooler line that can separate in cold temperatures under high load, spilling transmission fluid and creating a fire hazard. Going back to 1991 and 1992 models with console shift, the transaxle shift control cable can disengage from its bracket, causing the gear indicator to show Park when the transmission is still in gear, leaving the vehicle free to roll on an incline. The 1992 model also has a parking brake lever that can slip one or more teeth and fail to hold the vehicle on a slope.
On 1987 models, a fusible link near the windshield washer bottle bracket can melt under high electrical load and ignite the plastic bracket, causing an underhood fire. Also on 1987 vehicles, the accelerator cable can bind with excessive friction, preventing the throttle from returning to idle when the driver releases the pedal. Fog-lamp-equipped 1987 models have a headlamp circuit breaker that can overheat and cause the headlights and fog lamps to cut out suddenly at night or in poor weather.
