2004 Chevrolet Malibu
Problems, recalls and owner-reported issues
Steering is the leading concern among 1,697 owner complaints filed for this model year. This is the highest complaint count among 26 Malibu model years with reports.
Of the 2004 reports, 81 involved a crash and 15 involved a fire. 55 people were injured.
What owners report most often
Recalls and investigations
SteeringJul 21, 2014
Dorman Products, Inc. (Dorman) is recalling certain replacement intermediate steering shafts sold under the Dorman, OE Solutions, and Solutions brand names, part numbers 425-167, 2425167, and 7-3074, for installation on 2004-2012 Chevrolet Malibu, 2005-2010 Pontiac G6, and 2007-2009 Saturn Aura vehicles. The affected steering shafts may have a yoke that inadequately supports the u-joint bearing resulting in a premature failure.
A joint bearing that fails prematurely may cause separation of the u-joint resulting in a complete loss of steering control, increasing the risk of a crash.
Dorman will notify owners, and dealers will refund the purchase price or replace the steering shafts, free of charge. The recall began in September 2014. Owners may contact Dorman customer service at 1-800-523-2492.
Campaign 14E044000 on NHTSA.gov
Electrical system, wiringMay 14, 2014
General Motors LLC (GM) is recalling certain model year 2004-2012 Chevrolet Malibu vehicles manufactured May 16, 2003, through October 11, 2012, 2004-2007 Malibu Maxx vehicles manufactured June 25, 2003, through April 5, 2007, 2005-2010 Pontiac G6 vehicles manufactured May 26, 2004, through January 4, 2010, and 2007-2010 Saturn Aura vehicles manufactured April 24, 2006, through May 26, 2009. In the affected vehicles, increased resistance in the Body Control Module (BCM) connection may result in voltage fluctuations in the Brake Apply Sensor (BAS) circuit. These fluctuations can cause one or more of these conditions: the brake lights to illuminate without the brake pedal being pushed; the brake lights to not illuminate when the pedal is pushed; difficulty disengaging the cruise control; moving the gear shifter out of the 'PARK' position without pushing the brake; and disablement of crash avoidance features such as traction control, electronic stability control, and panic braking assist features.
Any of the above failure conditions increases the risk of a crash.
GM will notify owners, and dealers will attach the wiring harness to the BCM with a spacer, apply dielectric lubricant to both the BCM and harness connector and the BAS and harness connector, and will relearn the brake pedal home position, free of charge. The manufacturer distributed an Interim letter to customers on July 14, 2014. The recall began on August 18, 2014. Owners may contact General Motors customer service at 1-800-222-1020 (Chevrolet), 1-800-762-2737 (Pontiac), 1-800-553-6000 (Saturn). GM's number for this recall is 13036.
Campaign 14V252000 on NHTSA.gov
Power train, automatic transmissionApr 30, 2014
General Motors LLC (GM) notified the agency on April 29, 2014, that they are recalling 56,214 model year 2007 and 2008 Saturn Aura vehicles. On May 22, 2014, GM increased the recall to include an additional 1,074,899 model year 2004-2008 Chevrolet Malibu vehicles manufactured from May 16, 2003, through October 5, 2007, model year 2004-2007 Malibu Maxx vehicles manufactured from June 25, 2003, through April 5, 2007, and model year 2005-2008 Pontiac G6 vehicles manufactured from May 26, 2004, through September 28, 2007, and equipped with 4-speed transmissions. The total number vehicles being recalled is now 1,131,113.
If the transmission shift cable fractures while the vehicle is being driven, the transmission gear selection may not match the indicated gear and the vehicle may move in an unintended or unexpected direction, increasing the risk of a crash. Furthermore, when the driver goes to stop and park the vehicle, despite selecting the PARK position, the transmission may not be in PARK. If the vehicle is not in the "PARK" position there is a risk the vehicle will roll away as the driver and other occupants exit the vehicle or anytime thereafter. A vehicle rollaway increases the risk of injury to exiting occupants and bystanders.
GM will notify owners, and GM dealers will replace the shift cable assembly and mounting bracket, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact General Motors at 1-800-553-6000. GM's number for this recall is 14152.
Campaign 14V224000 on NHTSA.gov
Steering, electric power assist systemMar 31, 2014
General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009 Pontiac G6. In the affected vehicles, there may be a sudden loss of electric power steering (EPS) assist that could occur at any time while driving.
If power steering assist is lost, greater driver effort would be required to steer the vehicle at low speeds, increasing the risk of a crash.
GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When parts are available, owners will be mailed a second letter to come in to have the applicable bulletin applied. Bulletin 14115 covers model year 2004-2007 Saturn Ion, 2009-2010 Chevrolet HHR and 2010 Chevrolet Cobalts. Dealers will replace the EPS motor. Bulletin 14116 covers model year 2004-2006 Chevrolet Malibu and Malibu Maxx, 2005-2006 Pontiac G6 and 2008-2009 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from March 1, 2008, through June 27, 2008. Dealers will replace the torque sensor assembly. Bulletin 14117 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from February 1, 2008, through February 28, 2008. Dealers will replace the torque sensor assembly and EPS motor controller unit. Bulletin 14118 covers model year 2008 Chevrolet Malibu, Pontiac G6 and Saturn Aura built from October 1, 2007, through January 31, 2008. Dealers will replace the EPS motor controller unit. The recall began on July 17, 2014. Owners may contact Chevrolet at 1-800-630-2438, Saturn at 1-800-553-6000, and Pontiac at 1-800-620-7668. GM's number for this recall is N140115. Note: GM bulletin number 14119 will be implemented for model year 2006-2008 and early production of 2009 Chevrolet HHR (non-turbo) and model year 2003 Saturn ION to provide EPS Motor replacement for the life of the vehicle.
Campaign 14V153000 on NHTSA.gov
Fuel system, gasoline, delivery, fuel pumpFeb 28, 2011
TI AUTOMOTIVE IS RECALLING CERTAIN FUEL PUMPS, PART NUMBERS TU456 AND TU303, SOLD UNDER VARIOUS BRAND NAMES AS AFTERMARKET AND REPLACEMENT EQUIPMENT FOR THE MOTOR VEHICLES LISTED ABOVE. THE DEFECTIVE FUEL PUMP MAY SEIZE, STOPPING THE FUEL FLOW TO THE ENGINE CREATING A STALLING CONDITION.
A VEHICLE CRASH COULD OCCUR SHOULD THE ENGINE STALL WHILE IN USE.
TI AUTOMOTIVE WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE ANY DEFECTIVE FUEL PUMP WITH A NEW OR REWORKED FUEL PUMP FREE OF CHARGE. THE SAFETY RECALL BEGAN ON FEBRUARY 22, 2011. OWNERS MAY CONTACT TI AUTOMOTIVE AT 1-866-867-3759 OR LOG ON TO WWW.RECALLRESPONSE.COM.
Campaign 11E009000 on NHTSA.gov
Exterior lightingApr 7, 2009
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
Campaign 09E012000 on NHTSA.gov
Service brakes, hydraulic, antilock/traction control/electronic limited slip, control unit/moduleApr 19, 2004
SOME OF THESE PASSENGER VEHICLES HAVE AN ELECTRONIC CONTROL UNIT (ECU) THAT MAY CALCULATE A HIGHER THAN ACTUAL VEHICLE SPEED BECAUSE OF AN ERRATIC REAR-WHEEL SPEED SENSOR SIGNAL, AND CAUSE ABS ACTIVATION WHERE IT IS NOT NEEDED OR NEEDED ABS ACTIVATION TO BE EXTENDED DURING BRAKING AS THE VEHICLE SPEED DROPS TO ABOUT 3 MPH.
UNEXPECTED ABS ACTIVIATION COULD INCREASE STOPPING DISTANCE UP TO ABOUT 11 FEET DPENDING ON THE GRADE OF THE ROAD, INCREASING THE RISK OF A CRASH.
DEALERS WILL REPROGRAM THE ABS CONTROLLER. OWNER NOTIFICATION BEGAN ON JUNE 16, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438.
Campaign 04V190000 on NHTSA.gov
Seat belts, front, anchorageApr 16, 2004
ON CERTAIN PASSENGER VEHICLES, ANALYSIS OF AN A SIDE IMPACT CRASH TEST CONDUCTED BY THE NHTSA;S NEW CAR ASSESSMENT PROGRAM (NCAP) INDICATED THAT THE OUTBOARD ANCHORAGE OF THE DRIVER'S SEAT BELT COULD DISCONNECT BECAUSE OF CONTACT BETWEEN THE SEAT TRIM AND THE ANCHORAGE CONNECTOR WHEN THE SEAT WAS ADJUSTED TO ITS LOWEST POSITION.
IF THIS OCCURRED IN A CRASH, THE DRIVER COULD RECEIVE GREATER INJURIES.
DEALERS WILL INSERT A RETAINER ON BOTH THE DRIVER'S AND PASSENGER'S BELT ANCHORAGES. OWNER NOTIFICATION BEGAN ON JUNE 16, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438.
Campaign 04V188000 on NHTSA.gov
Equipment, other, labelsFeb 24, 2004
CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 208, "OCCUPANT CRASH PROTECTION." SOME OF THESE VEHICLES THAT WERE NOT EQUIPPED WITH AN ADVANCED OCCUPANT RESTRAINT SYSTEM (AORS) HAVE DRIVER AND PASSENGER SIDE SUN VISORS WITH AORS LABELS. THE AORS LABELS DO NOT INCLUDE STATEMENTS AND THE ILLUSTRATION REQUIRED BY FMVSS NO. 208 FOR VEHICLES WITHOUT AORS.
OWNERS WILL BE SENT REPLACEMENT LABELS WITH INSTRUCTIONS ON HOW TO INSTALL THEM. OWNER NOTIFICATION BEGAN ON APRIL 21, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438.
Campaign 04V094000 on NHTSA.gov
Representative owner complaints: exterior lighting
132 reports, newest first. Show all
Exterior lighting, May 2, 2006
DT*: THE CONTACT STATED THE RIGHT FRONT TURN SIGNAL STOPPED WORKING WITHOUT WARNING. UPON INITIAL INSPECTION, THE AMBER LENS INSIDE THE HEADLIGHT HOUSING HAD VISIBLE DAMAGE ON THE HEADLIGHT ASSEMBLY AS THOUGH IT HAD BURNED. THERE WERE NO VISIBLE FLAMES OR SMOKE TO INDICATE A FIRE. THE DEALER WAS ALERTED, BUT NO REPAIRS WERE MADE.
Exterior lighting, Jul 29, 2005
LEFT TURN SIGNAL INOP. REPLACED UNDER WARRANTY. FAILURE AGAIN WITHIN AN HOUR OF LEAVING DEALERSHIP. *NM
Exterior lighting, May 26, 2005
I OWN A 2004 CHEVY MALIBU MAXX, WHICH HAS AUTOMATIC HEADLIGHTS. WHEN THE HEADLIGHTS WORK IN AUTOMATIC MODE, EVERYTHING WORKS FINE. UNFORTUNATELY THE SOLAR SENSOR THAT ACTIVATES THEM "THINKS" THE SKY IS BRIGHT WHEN IT IS VERY OVERCAST. FOR THE MOST PART NOT A PROBLEM, AS YOU CAN TURN THE LIGHTS ON MANUALLY. UN-FORTUNATELY, THE DASH-BOARD LIGHTS DO NOT COME ON WHEN YOU DO THIS, UNLESS THE SENSOR "THINKS" IT'S DARK. TO REMEMDY THIS, I PUT SOMETHING OVER THE SENSOR, BUT SHOULD NOT HAVE TO, AND IF I DON'T, EVEN THOUGH I CAN SEE IN FRONT OF MY CAR, I CAN'T SEE HOW FAST I'M GOING, TACHOMETER, BATTERY METER READINGS, ETC. WHEN I TOOK THE VEHICLE FOR SERVICE, THEY REPLACED THE BODY CONTROL MODULE 3 TIMES, TOLD ME IT WAS FIXED, I WENT TO PICK IT UP, SAME THING HAPPENED. WE GOT INTO ANOTHER MALIBU, AND IT HAPPENED WITH THAT CAR AS WELL. IN OTHER WORDS THE SYSTEM IS WORKING THE WAY IT WAS DESIGNED. UNFORTUNATELY, THAT DOES NOT MEAN IT IS WORKING CORRECTLY. I BELIEVE THIS TO BE A SAFETY ISSUE AS I CAN NOT SEE DASH INDICATORS WHEN I NEED TO TURN THE LIGHTS ON MANUALLY. I ALSO OWN A 2002 CHEVROLET AVALANCHE WITH AUTOMATIC HEADLIGHTS, AND THIS PROBLEM DOES NOT EXIST. I'VE ALSO OWNED A 1998 CHEVROLET MALIBU WITH AUTOMATIC HEADLIGHTS, AND THIS PROBLEM DID NOT EXIST. MY FRIEND OWNS A 2004 GMC YUKON WITH AUTOMATIC HEADLIGHTS, AND IT DOES NOT EXIST ON THAT EITHER. IT APPERS TO BE ONLY WITH THE THE 2004 (AND POSSIBLY ABOVE) MALIBU, AND POSSIBLY ONLY THE MALIBU MAXX. I WOULD APPRECIATE ANY HELP THAT YOU MAY BE ABLE TO PROVIDE. THANK YOU IN ADVANCE.
Exterior lighting, Apr 28, 2005
I BOUGHT THE 2004 MALIBU IN JUNE 2004. IN JANUARY 2005, THE FRONT DRIVER'S SIDE TURN SIGNAL AND HEADLIGHT STOPPED WORKING. I TOOK IT TO THE NEAREST SHOP, AND THEY REPLACED THE BULBS. A FEW WEEKS LATER, IT HAPPENED A SECOND TIME. THEY REPLACED THE BULBS AGAIN. WHEN IT HAPPENED THE THIRD TIME I ASKED FOR FURTHER INVESTIGATION INTO THE PROBLEM, INCLUDING WIRING. THEY DISCOVERED THE WHOLE LIGHT CARRIAGE NEEDED TO BE REPLACED. PROBLEM FIXED. IN MARCH 2005, THE REAR DRIVER'S SIDE LIGHT DID THE SAME THING. THE ENTIRE CARRIAGE WAS REPLACED. IT JUST SEEMED A BIT EXCESSIVE FOR A CAR LESS THAN A YEAR OLD.*AK
Steering, Power train, Electrical system, Exterior lighting, Nov 11, 2004
I HAVE HAD MANY PROBLEMS WITH MY 04 MALIBU. ROUGH IDLE, POWER STEERING FALIURE MANY TIMES TOOK TO DEALER 3 TIMES COULD NOT DUPLICATE, BROUGHT IN WITH POWER STEERING OUT AT IT WAS DUPLICATED, BUT COULD NOT FIGURE OUT FOR A WHILE TOLD ME TO CONTINUE TO DRIVE, NO SAFETY FACTOR.FINALLY THOUGHT THEY FIGURED OUT PUT IN A NEW STEERING COLUMN, 9,000 MILES LATER BACK TO HAVING PROBLEMS WITH POWER STEERING. ALSO PROBLEMS WITH HARD SHIFTING,AND ALSO WITH IGNITION STICKING OR CONTINUING TO TURN OVER AFTER LEETING GO OF THE KEY. I WOULD NOT RECOMEND THIS CAR TO ANYONE AND THEY SHOULD ALL BE CRUSHED.MY WIFE IS TERRIFIED OF THE CAR AND WILL NOT DRIVE.CAR IS AT DEALER RIGHT NOW WE ARE DRIVING A LOANER. *JB EA04018_CAT
Steering, Exterior lighting, Other or unspecified, Nov 3, 2004
WHILE DRIVING POWER STEERING PUMP FAILED . THE CONSUMER TOOK THE VEHICLE TO DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT THE POWER STEERING PUMP NEEDED TO BE REPLACED. *AK EA04018_CAT CURRENTLY THE VEHICLE STILL DOES NOT STEER PROPERLY. THE VEHICLE WAS TAKEN FOUR TIMES BEFORE THE SERVICE DEALER TO SAY IT WAS OKAY. THE HEADLIGHTS SHINED TOO HIGH, THERE WAS A VIBRATION WHEN THE VEHICLE WAS IN MOTION AND WAS UNABLE TO BE DUPLICATED. *SC
Electrical system, Exterior lighting, Latches/locks/linkages, Equipment, Aug 30, 2004
CONSUMER COMPLAINED ABOUT AN ELECTRICAL PROBLEM. CONSUMER TOOK VEHICLE TO DEALERSHIP AND HAD THE WORK DONE ON JULY 1, 2004. VEHICLE HAD ONLY 100 MILES. ON AUGUST 13,2004 THE DASHBOARD LIGHTS FAILED, AND THE TAIL LIGHTS WERE OUT. ON AUGUST 23, VEHICLE HAD THE SAME PROBLEM. CONSUMER PARKED THE VEHICLE AND THE LOCKS AUTOMATICALLY UNLOCKED WHILE THE VEHICLE WAS STILL RUNNING. ALSO, THE AIR CONDITIONER WAS RUNNING WHEN THE KEY WAS NOT IN THE IGNITION. *AK