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: hydraulic
42 reports, newest first. Show all
Steering, Service brakes, Hydraulic, Equipment, Dec 12, 2005, crash
ON DECEMBER 2, 2005 I WAS TRAVELING TO WORK USING MY TYPICAL ROUTE HIGHWAY 74 ALSO KNOWN AS THE ORTEGA HIGHWAY WHEN COMING TO A SHARP AND NARROW CURVE MY BRAKE PEDAL DID NOT WORK AND MY STEERING WAS LOCKED. I WAS NOT ABLE TO CONTROL THE DIRECTION OF MY VEHICLE AS A RESULT THE VEHICLE MERGED TO ON COMING TRAFFIC AND TUMBLED FOUR TIMES . *NM
Steering, Service brakes, Hydraulic, Dec 7, 2005, crash
DT: THE CONTACT STATED THE BRAKES AND STEERING MALFUNCTIONED, RESULTING IN AN ACCIDENT. THE STEERING LOCKED UP WHILE ATTEMPTING TO MAKE A RIGHT TURN. PRIOR TO THIS INCIDENT SHE HEARD A SQUEAKING NOISE IN THE BRAKES. SHE TOOK THE CAR TO A MECHANIC, AND WAS TOLD BRAKES WERE IN GOOD WORKING CONDITION. SHE HAS NOT CONTACTED THE DEALERSHIP. A POLICE REPORT WAS TAKEN. . THE CONTACT SUFFERED A CONCUSSION, AND HAD NERVE DAMAGE. *AK UPDATED 12/30/05. *JB
Service brakes, Hydraulic, Sep 28, 2005
CONSUMER BRAKE ROTORS BEGAN TO WARP AFTER ONLY 20000 MILES. *TS THE CONSUMER WAS TOLD THE ROTORS ON THE VEHICLE WHICH WERE ALUMINUM COULD NOT BE PROPERLY RESURFACED. THE MANUFACTURER DISCONTINUED THE USE OF THOSE PARTICULAR ROTORS AND THE COST TO REPLACE THEM WAS 900.00 *JB
Service brakes, Hydraulic, Sep 2, 2005
2004 CHEVROLET MALIBU HAS RUSTED ROTORS.*MR THE DEALER TOLD THE CONSUMER THE PROBLEM WAS NORMAL. *JB
Service brakes, Hydraulic, Jul 31, 2005
BRAKE PEDAL SUDDENLY HAD NO RESISTANCE. IT HAPPENED WHEN THE VEHICLE WAS IN PARK SO THERE WERE NO CONSEQUENCES. IF IT HAPPENED WHILE DRIVING, THERE WOULD BE NO WAY TO STOP THE VEHICLE. UPON VISUAL INSPECTION, THE BRAKE PEDAL PUSHROD WAS DISCONNECTED FROM THE BRAKE PEDAL. THE CAUSE APPEARS TO BE THAT THE BRAKE PEDAL PUSHROD RETAINER WAS MISSING. *NM
Service brakes, Hydraulic, Jun 20, 2005
CHEVROLET MALIBU MODEL USES INFERIOR BRAKE ROTORS CAUSING ROTORS TO BE WARPED ALMOST IMMEDIATELY UPON INSTALLATION ON VEHICLE. UPON TAKING DELIVERY OF 2004 CHEVROLET MALIBU IN JULY 2004 IT WAS IMMEDIATELY APPARENT THAT THE FRONT BRAKE ROTOR WAS WARPED CAUSING UNSAFE BRAKING CONDITIONS AND A GENERAL UNEASYNESS WHEN DRIVING. CAR WAS RETURNED TO DEALER, AND ONLY OFFER ON THIS BRAND NEW CAR WAS THE RESURFACE THE ROTORS. THIS FIX, WHILE TEMPORARILY EFFECTIVE, TO ME IS NOT ACCEPTABLE ON A NEW FROM THE FACTORY CAR. THE SAME CAR HAS 18000 MILES NOW, AND THE PROBLEM HAS AGAIN RESURFACED. UPON FURTHER RESEARCH ONLINE, THIS PROBLEM APPEARS TO BE FAIRLY WIDESPREAD. I HAVE NOT RETURNED TO THE DEALER TO HAVE IT CHECKED YET, BUT THIS IS ISSUE IS NOT LIKELY TO BE HAVE BEEN CAUSE BY POOR DRIVING HABITS BY THE USER. I HAVE ANOTHER AUTOMOBILE THAT WENT OVER 50000 MILES ON IT'S ORIGINAL ROTORS AND EVEN AT THAT POINT THE ROTORS WERE NOT WARPED.
Steering, Service brakes, Hydraulic, Jan 16, 2005
I OWN A 2004 CHEVROLET MALIBU. AT PRESENT TIME, I HAVE HAD TO HAVE THE STEERING COLUMN REPLACED TWICE, DUE TO INTERMITTENT POWER STEERING FAILURE AND A CONSTANT PULL TO THE LEFT. THE FIRST TIME WAS AT APPROXIMATELY 8800 MILES, THE SECOND TIME AT 17700 MILES. I HAVE ALSO HAD TO HAVE THE BRAKE ROTORS AND PADS REPLACED TWICE. THE BRAKES STILL MAKE A RUBBING NOISE IN THE RIGHT FRONT, HOWEVER THE DEALERS TELLS ME THEY CANNOT FIX THAT. THE CAR CURRENTLY HAS 18000 MILES ON IT. I STILL HAVE STEERING ISSUES, SUCH AS TWITCHES IN THE STEERING WHEEL AND THUNKS AND CLUNKS WHEN DRIVING. I AM VERY UNCOMFORTABLE DRIVING THE CAR BECAUSE I AM AFRAID THE STEERING WILL GO OUT AGAIN. *NM
Steering, Service brakes, Hydraulic, Nov 10, 2004
WHEN COMING TO A STOP POWER STEERING FAILED, AND THE STEERING WHEEL LOCKED UP. CONSUMER HAD TO RESTART THE VEHICLE TO STOP. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK EA04018_CAT FOUND THE WHEEL POSITION SENSOR NOT READING CONSISTENTLY. THERE WAS AN INTERMITTENT GRINDING NOISE. *SC
Service brakes, Hydraulic, Nov 5, 2004
A RECALL FOR THE ABS SYSTEM WAS ISSUED.CONSUMER WAS WAITING FOUR MONTHS.*AK
Service brakes, Hydraulic, Oct 5, 2004
AT 34 MILES ON THE CAR ABS/TRACTION CONTROL SENSOR IN THE WHEEL HUB FAILED, CAUSING SEVERAL TROUBLE LIGHTS TO COME ON AND A SOUND SIGNAL TO INDICATE THERE WAS A PROBLEM. THE OWNERS MANUAL NOTED THAT THE CAR SHOULD BE TOWED TO THE DEALERSHIP.*AK
Steering, Service brakes, Hydraulic, Sep 14, 2004
WHILE STOPPED AT A RED LIGHT THE VEHICLES TILT STEERING UNLOCKED WITHOUT WARNING. AS A RESULT THE VEHICLE BEGAN TO ROLL FORWARD EVEN WITH THE BRAKES APPLIED. *JB THE VEHICLES ABS LIGHT WOULD ILLUMINATE WHEN THE VEHICLE WAS DRIVEN. THE LIGHT WOULD GO OFF ONCE THE VEHICLE WAS PARKED, TURNED OFF THEN TURNED BACK ON. *NM
Service brakes, Hydraulic, Sep 8, 2004
AFTER HAVING THE STEERING COLUMN REPLACED IN MY 2004 CHEVROLET MALIBU, I NOTICED THE BRAKE PEDAL IS NOT RELEASING ALL THE WAY. THIS ONLY HAPPENS ON THE FREEWAY, SO FOR SOME REASON ONLY WHEN THE CAR EXCEEDS 50 MILES. I REPORTED THIS PROBLEM TO THE DEALER AND THEY SAID THEY COULDN'T FIND ANYTHING WRONG WITH THE BRAKES. NOW I AM CONCERNED THAT MY BRAKES WITH BE HARMED IF THEY ARE NOT RELEASING LIKE THEY SHOULD. *AK
Service brakes, Hydraulic, Jul 30, 2004, crash
THE VEHICLE ABS CONTROL MODULE FAILED PRIOR TO THE CONSUMER ACTING ON THE NOTICE RECEIVED ON JUNE 21 ( NHTSA#04V190000). THE FAILURE RESULTED IN AN ACCIDENT ON JUNE 28, 2004 WHILE DRIVING BETWEEN 20 TO 25 MPH. THE CONSUMER APPLIED THE BRAKE BUT THE ABS DID NOT ACTIVATE. AS A RESULT THE DRIVER HIT THE BACK OF THE VEHICLE IN FRONT OF HIM. *NM *NM
Steering, Service brakes, Hydraulic, Jul 12, 2004
WHILE DRIVING MY 2004 CHEVY MALIBU MY STEERING WHEEL STARTED TO JERK BACK AND FORTH, THIS WOULD HAPPEN WHEN TURNING RIGHT. AT LOW SPEEDS. I ALSO HAD THE ABS BRAKE LIGHT COME ON INTERMITTENTLY, THE DEALERSHIP WAS ABLE TO VERIFY THE BRAKE LIGHT PROBLEM DUE TO A RECALL AND THE STEERING ALSO WAS VERIFIED. THIS RESULTED IN REPLACEMENT OF THE "RACK IS WHAT THE DEALER CALLED IT." I HAVE NOTICED THIS IS A PROBLEM ON MANY 2004 MALIBUS. CHEVROLET HAD BETTTER LOOK INTO THISAND TAKE APPROPRIATE ACTION BEFORE IT RESULTS IN DEATH AND MAJOR LEGAL ACTION. EA04018_CAT. *LA
Service brakes, Hydraulic, May 11, 2004
WHILE APPROACHING A STOP SIGN CONSUMER APPLIED THE BRAKES AND PASSENGER SIDE WHEEL LOCKED UP. CONSUMER WAS UNABLE TO UNLOCK THE WHEEL. CONSUMER HAD THE VEHICLE TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC DETERMINED THAT THE MAIN BOLT SHEARED OFF. THIS CAUSED THE CALIPER TO LOCK THE WHEEL. ALSO, MECHANIC INFORMED THE CONSUMER THAT THE PART WAS ON BACK ORDER. *AK *NM
Steering, Service brakes, Hydraulic, Electrical system, Apr 13, 2004
WHILE DRIVING AT ANY SPEED AND WITHOUT WARNING, THE VEHICLE LOST POWER STEERING. THIS PROBLEM HAPPENED FOUR TIMES IN FOUR MONTHS. THE VEHICLE WAS TAKEN TO A DEALER, WHO REPLACED THE STEERING COLUMN UNIT. ALSO, THE ABS LIGHT CAME ON AND THE BRAKES MADE A SCREECHING NOISE WHEN DEPRESSED. THE DEALER REPLACED THE ABS MODULE AND FRONT BRAKE HUBS. ALTHOUGH THE REPAIRS HAD BEEN DONE, THE SAME PROBLEMS RECURRED. *AK THERE WERE ELECTRICAL FAILURES WITH THE DASH DIMMER SWITCH AND HEADLIGHT DIMMER, THE KEYLESS ENTRY NEEDED TO BE REPLACED AND GREASE LEAKED FROM THE LEFT FRONT WHEEL. *SC PE04031_CAT *JB
Service brakes, Hydraulic, Mar 10, 2004
ROTORS WERE REPLACED AT 17,000 MILES BECAUSE THEY WERE WARPED. THEN AT 46,000 MILES THERE WAS NEW PADS PUT ON THE FRONT OF CAR,AND ROTORS WERE MACHINED AT THIS TIME,AS REGULAR MAINTENANCE. NOW AT 60,000 MILES THE ROTORS NEED REPLACED AGAIN. THERE IS A PROBLEM HERE AND CHEVROLET NEEDS TO REALIZE IT. CARS DON'T GO THROUGH ROTORS EVERY 20,000 MILES. THIS GETS EXPENSIVE ONCE THE CAR IS OUT OF WARRANTY. BUT CHEVY SAYS ITS JUST HOW IT IS. *AK