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: seats
163 reports, newest first. Show all
Seats, Feb 8, 2010
POWER DIRVER SEAT ON 2004 CHEVY MALIBU MAXX BROKE CAUSING THE SEAT TO LEAN TO THE RIGHT.
Seats, Dec 2, 2009
2004 CHEVROLET MALIBU LT SEDAN FAILURE: WELD UNDER DRIVER SEAT BROKE IN TWO PLACES. CAUSES SEAT TO SET LOWER ON ONE SIDE PLACING DRIVER AT AWKWARD POSITION TO CONTROLS. IF A COLLISION OCCURRED, THE SEAT WOULD FAIL CAUSING THE DRIVER TO BE THROWN WHO KNOWS WHERE. CORRECTION: SEAT REMOVED FOR INSPECTION, MUST BE REPLACED AS UNABLE TO REPAIR. *TR
Seats, Nov 25, 2009
MY ELECTRIC DRIVERS SEAT WAS NOT WORKING PROPERLY, SO I SET IT TO MY POSITION AND LEFT IT THAT WAY FOR OVER A YEAR. MY WIFE COMPLAINED ABOUT IT SO I REMOVED IT TO FIND THE BAD MOTOR ( ASSUMED) BUT FOUND THE MAIN CROSS MEMBER WELD BROKE. IF I HAD BEEN IN AN ACCIDENT, I MAY HAVE GONE THROUGH THE WINDSHIELD. CONTACTING GM AND THE LOCAL DEALER RESULTED IN NO CORRECTION. I PERSONALLY REPAIRED THE WELD, BUT SINCE THE TUBING WAS ALSO TORN, IT MAY NOT HOLD. MY CONCERN IS THAT OTHERS ARE NOT AWARE OF THIS WELD ISSUE AND BELIEVE LIKE ME THAT IT IS AN ELECTRIC FAILURE. *TR
Seats, Nov 20, 2009
I HAVE NOT BEEN ABLE TO DRIVE MY 2004 CHEVY MALIBU DUE TO THE SUPPORTS UNDER THE DRIVERS SEAT BREAKING ON ONE SIDE. IT IS A 6-WAY POWER SEAT AND THE BREAKAGE IS CAUSING THE ONE SIDE OF THE SEAT TO "FLOAT." IT IS NOT SECURE WHEN YOU HAVE THE SEAT RAISED OFF THE FLOOR. THE SEAT WILL MOVE WHEN YOU SHIFT IN YOUR SEAT, MAKE A TURN, OR GO OVER ANY BUMPS. NEW PARTS TO FIX THE SEAT COST $500 (NOT INCLUDING LABOR), FOR A FEW SCREWS AND SOME METAL BARS. SEARCHED JUNK YARDS FOR A REPLACEMENT SEAT AND NOTICED THE SAME ISSUE STARTING TO OCCUR ON SEVERAL SEATS THAT WERE THERE. ALSO INQUIRED WITH A MECHANIC WHO STATED THAT THIS IS A COMMON OCCURRENCE IN THE 2004 AND LATER MALIBU SEDANS, HE KNEW THE EXACT PART NUMBERS THAT NEEDED TO BE REPLACED WITHOUT EVEN SEEING THE CAR. I WOULD LIKE FOR CHEVROLET TO RECOGNIZE THIS AS A REAL SAFETY CONCERN. *TR
Structure, Seats, Oct 7, 2009
BOUGHT A CERTIFIED USED 2004 MALIBU MAXX IN AUGUST 2007 WITH 19000 MILES. CURRENTLY HAVE 68000 MILES. DRIVERS SEAT FRAME CRACKED. WAS NOT IN ANY ACCIDENT OR ANY INCIDENT WHICH COULD HAVE CAUSED THE FRAME TO CRACK. THE DRIVER SEAT IS 4 WAY ELECTRIC POWERED SEAT. *TR
Seats, Jul 16, 2009
DRIVERS SEAT FRAME BROKE AT WELD. SEAT WAS NO LONGER ATTACHED TO VEHICLE. ALMOST CAUSED ME TO HAVE AN ACCIDENT. $843 TO REPLACE THE FRAME. *TR
Seats, Sep 18, 2008
THE WELD BROKE ON THE DRIVER'S SEAT MOUNTING BRACKET. THERE WAS NO ABUSE OF THE SEAT TO CAUSE THIS TO FAIL. IT DID NOT CAUSE CRASH OR INJURY. THE DRIVERS SEAT MOUNTING BRACKET WAS REPLACED. *TR
Seats, Aug 12, 2008
TL*THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. WHILE DRIVING APPROXIMATELY 60 MPH, THE DRIVER'S SEAT DROPPED APPROXIMATELY 3 TO 4 INCHES ON THE RIGHT SIDE. THE CONTACT ARRIVED HOME AND DISCOVERED THAT THE BRACKET FAILED. THE CURRENT MILEAGE WAS 42,678 AND FAILURE MILEAGE WAS 42,653. UPDATED 09/10/08. *LJ THE SEAT FRAME WELD BROKE. UPDATED 09/12/08. *JB
Seats, Jul 17, 2008
SEAT BRACKET BROKE WHILE DRIVING CAUSING SEAT TO SUDDENLY DROP TO ONE SIDE. AS A RESULT, DRIVER NEARLY LOST CONTROL OF VEHICLE. INSPECTION OF THE SEAT MOUNT REVEALED TWO FAILED WELDS. CONTACTED GM THE NEXT DAY, THEN BROUGHT VEHICLE TO NEAREST DEALER AT GM'S REQUEST. DEALER INITIALLY REPORTED THAT THE PROBLEM WAS A CLEAR FACTORY DEFECT AND SUGGESTED THAT GM SHOULD REPAIR IT AT NO COST TO US. AFTER TWO WEEKS OF "CONSIDERING OUR REQUEST," GM DENIED THE CLAIM AND SUGGESTED THAT WE SHOULD HAVE PURCHASED AN EXTENDED WARRANTY. THE PROBLEM HAS NOT BEEN CORRECTED AT THIS TIME. *TR
Seats, Jun 16, 2008
WAS DRIVING WHEN DRIVERS SEAT LURCHED TO THE LEFT. WHEN I GOT HOME AND INSPECTED THE SEAT I OBSERVED THAT A WELD HAD BROKEN IN THE LOWER SEAT FRAME COMPONENT ASSOCIATED WITH VERTICAL HEIGHT ADJUSTMENT FOR POWER SEAT. *TR
Seats, May 13, 2008
WAS DRIVING ON EXIT RAMP ON LOCAL EXPRESSWAY WHEN DRIVERS SEAT LURCHED TO THE LEFT. WHEN I GOT HOME AND INSPECTED THE SEAT I OBSERVED THAT A WELD HAD BROKEN IN THE LOWER SEAT FRAME COMPONENT ASSOCIATED WITH VERTICAL HEIGHT ADJUSTMENT FOR POWER SEAT. *TR
Power train, Exterior lighting, Visibility, Vehicle speed control, Seats, Equipment, Steering, Mar 15, 2007
2004 MALIBU CUSTOMER HAS HAD PROBLEMS WITH LOSS OF ELECTRIC POWER STEERING AND WANTS OUT OF THE LEASE WITHOUT PENALTY**CC THE RADIO WAS INOPERATIVE, THE CRUISE CONTROL WAS INOPERATIVE AT TIMES, IT WOULD TURN OFF, BUT NOT ENGAGE. THE PCM WAS REPLACED. THE PASSENGER SIDE DIRECTIONAL LIGHTS AND BRAKE LIGHTS WERE INOPERATIVE. THE DEALER REPLACED THE BULBS. THE HEATED SEATS CAME ON BY THEMSELVES. THE INTERMEDIATE SHAFT WAS REPLACED, BECAUSE THE CONSUMER STATED THERE WAS A NOISE WHEN TURNING THE STEERING WHEEL. THE TRANSMISSION COOLING LINES WERE LEAKING, THE REAR DEFOGGER ON THE PASSENGER SIDE WAS INOPERATIVE. WHEN THE WINDSHIELD WIPERS WERE ON INTERMITTENT, THEY WOULD GO FULL SPEED BY THEMSELVES. *JB
Steering, Suspension, Engine and engine cooling, Electrical system, Latches/locks/linkages, Seats, Mar 8, 2007
I WENT TO THE DEALERSHIP AND TRADED MY SATURN VUE FOR THE 2004 MALIBU MAXX. WHEN I TEST DROVE THE CAR, AFTER THE ACCELERATION REACHED 4RPMS, THERE WAS A HIGH PITCHED WHINE FROM THE ENGINE CLOSEST TO THE TIRE. THEY LOOKED AT IT AND SAID THAT IT WAS A LOOSE BELT. SO I BOUGHT THE CAR AND THEY SAID TO BRING IT THE CHEVY DEALERSHIP TO GET IT FIXED. I TOOK IT IN AND THEY SAID THEY COULDN'T DUPLICATE THE PROBLEM SO I HAD TO RIDE WITH THEM. ALSO, MY SEAT HEATERS WERE TURNING ON AUTOMATICALLY, CAR CONSTINTLY PULLS TO THE RIGHT, I HAVE TO TURN THE KEY OVER FOR A LONG TIME TO GET THE CAR TO FULLY START UP. THEY COULDN'T DUPLICATE ANY OF THE PROBLEMS SO I AM STILL DEALING WITH ALL OF THEM. FOR THE WHINING NOISE, THEY SAID IT IS A DRIVE BELT THAT NEEDS TO BE REPLACED, BUT IT IS OUT OF STOCK. HOW CONVIENIENT. *JB