Model year record

2004 Chevrolet Malibu

6 recall campaigns on file for this model year. 1,641 owner complaints on file.

Recalls

Recall campaignNHTSA 14V252000

Electronic stability control (ESC)

Component: Electronic stability control (ESC)
Manufacturer: General Motors LLC
Vehicles affected: 2,440,524
Reported to NHTSA: 2014-05-14
Owners notified: 2014-08-18

Defect description

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.

Safety risk

Any of the above failure conditions increases the risk of a crash.

Manufacturer remedy

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.

Recall campaignNHTSA 14V224000

Power train: automatic transmission: lever and linkage: floor shift

Component: Power train: automatic transmission: lever and linkage: floor shift
Manufacturer: General Motors LLC
Vehicles affected: 1,131,113
Reported to NHTSA: 2014-04-30
Owners notified: 2014-06-27

Defect description

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.

Safety risk

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.

Manufacturer remedy

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.

Recall campaignNHTSA 14V153000

Steering: electric power assist system

Component: Steering: electric power assist system
Manufacturer: General Motors LLC
Vehicles affected: 1,373,177
Reported to NHTSA: 2014-03-31
Owners notified: 2014-07-17

Defect description

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.

Safety risk

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.

Manufacturer remedy

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.

Recall campaignNHTSA 04V190000

Service brakes, hydraulic: antilock/traction control/electronic limited slip: control unit/module

Component: Service brakes, hydraulic: antilock/traction control/electronic limited slip: control unit/module
Manufacturer: GENERAL MOTORS CORP.
Vehicles affected: 65,439
Reported to NHTSA: 2004-04-19
Owners notified: 2004-06-16

Defect description

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.

Safety risk

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.

Manufacturer remedy

DEALERS WILL REPROGRAM THE ABS CONTROLLER. OWNER NOTIFICATION BEGAN ON JUNE 16, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438.

Recall campaignNHTSA 04V188000

Seat belts: front: anchorage

Component: Seat belts: front: anchorage
Manufacturer: GENERAL MOTORS CORP.
Vehicles affected: 84,474
Reported to NHTSA: 2004-04-16
Owners notified: 2004-05-07

Defect description

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.

Safety risk

IF THIS OCCURRED IN A CRASH, THE DRIVER COULD RECEIVE GREATER INJURIES.

Manufacturer remedy

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.

Recall campaignNHTSA 04V094000

Equipment: other: labels

Component: Equipment: other: labels
Manufacturer: GENERAL MOTORS CORP.
Vehicles affected: 51,715
Reported to NHTSA: 2004-02-24
Owners notified: 2004-04-21

Defect description

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.

Manufacturer remedy

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.

Owner complaints

A complaint is one person's report to a federal agency. It is not a finding.

Component	Complaints	Median mileage
Steering	717	80,000 mi
Steering: electric power assist system	139	8,379 mi
Electrical system	117	90,000 mi
Seats	68	96,000 mi
Exterior lighting	60	82,000 mi
Power train	49	112,000 mi
Steering: column	43	20,000 mi
Service brakes	30	100,000 mi
Air bags	24	91,000 mi
Vehicle speed control	23	91,000 mi
Electronic stability control (ESC)	21	129,662 mi
Suspension	21	33,500 mi
Unknown or other	19	140,000 mi
Engine	17	125,000 mi
Engine and engine cooling	16	29,000 mi
Exterior lighting: turn signal	13	44,532 mi
Fuel/propulsion system	13	153,000 mi
Steering: hydraulic power assist system	13	34,000 mi
Electrical system: ignition	12	100,000 mi
Seat belts	12	48,000 mi
Fuel system, gasoline	10	80,000 mi
Service brakes, hydraulic	10	37,500 mi
Electrical system: ignition: switch	8	50,000 mi
Steering: column locking: anti-theft device	8	4,000 mi
Wheels	8	146,312 mi
Electrical system: horn	7	26,700 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip	7	5,500 mi
Steering: rack and pinion	7	41,200 mi
Suspension: front	7	40 mi
Exterior lighting: headlights	6	35,000 mi
Equipment	5	9,225 mi
Latches/locks/linkages: doors: latch	5	13,035 mi
Power train: automatic transmission	5	34,000 mi
Service brakes, hydraulic: foundation components: disc: rotor	5	15,000 mi
Fuel system, other: storage: fuel gauge system	4	45,000 mi
Power train: axle assembly: axle shaft: seal	4	15,000 mi
Vehicle speed control: cruise control	4	12,000 mi
Electrical system: ignition: anti-theft: control module	3	53,000 mi
Equipment: appliance: air conditioner	3	3,057 mi
Equipment: electrical: radio/tape deck/CD etc.	3	—
Latches/locks/linkages	3	44,462 mi
Power train: automatic transmission: control module (TCM/PCM/TECM)	3	4,383 mi
Service brakes, electric	3	60,000 mi
Service brakes, hydraulic: pedals and linkages	3	46,000 mi
Structure	3	50,000 mi
Visibility: power window devices and controls	3	2,500 mi
Air bags: frontal	2	7,100 mi
Electrical system: instrument cluster/panel	2	48,000 mi
Electrical system: wiring	2	4,543 mi
Engine and engine cooling: engine	2	2,000 mi
Exterior lighting: brake lights	2	4,383 mi
Exterior lighting: headlights: concealment devices	2	44,000 mi
Exterior lighting: turn signal: switch	2	4,383 mi
Fuel system, gasoline: delivery: fuel pump	2	45,000 mi
Interior lighting	2	47,000 mi
Parking brake	2	300 mi
Power train: automatic transmission: lever and linkage: column shift	2	1,500 mi
Service brakes, hydraulic: antilock/traction control/electronic limited slip: control unit/module	2	5,700 mi
Steering: gear box: shaft sector	2	2,500 mi
Steering: linkages: tie rod assembly	2	29,000 mi
Steering: rack and pinion: rack	2	23,800 mi
Structure: body: trunk lid	2	1,500 mi
Suspension: front: wheel bearing	2	45,000 mi
Tires	2	15,000 mi
Air bags: side/window	1	8,900 mi
Child seat	1	91,000 mi
Electrical system: alternator/generator/regulator	1	200,000 mi
Electrical system: starter assembly	1	—
Electrical system: wiring: interior/under dash	1	3,057 mi
Electronic stability control: automatic (ASC)	1	5,000 mi
Engine and engine cooling: cooling system	1	300 mi
Engine and engine cooling: exhaust system	1	33,751 mi
Equipment: electrical: anti-theft devices	1	23,000 mi
Equipment: mechanical: accessory scissor/screw/bottle jack/lift	1	19,000 mi
Exterior lighting: brake lights: switch	1	169,000 mi
Exterior lighting: hazard flashing warning lights	1	98,000 mi
Exterior lighting: tail lights	1	53,000 mi
Exterior lighting: tail lights: switch	1	3,057 mi
Exterior lighting: turn signal: flasher unit	1	—
Forward collision avoidance: automatic emergency braking	1	50,000 mi
Fuel system, gasoline: delivery: hoses, lines/piping, and fittings	1	62,000 mi
Fuel system, gasoline: fuel injection system	1	—
Power train: automatic transmission: lever and linkage: floor shift	1	34,517 mi
Power train: clutch assembly	1	54,350 mi
Power train: driveline	1	109,000 mi
Power train: driveline: driveshaft	1	149,000 mi
Seat belts: front	1	100,000 mi
Seat belts: front: anchorage	1	—
Seats: front assembly: seat heater/cooler	1	—
Service brakes, air: antilock: ABS warning light	1	1,800 mi
Service brakes, hydraulic: foundation components: disc: caliper	1	3,400 mi
Steering: gear box (other than rack and pinion)	1	—
Steering: linkages	1	17,500 mi
Structure: body: door	1	118,000 mi
Structure: frame and members	1	100,000 mi
Structure: frame and members: underbody shields	1	18,563 mi
Suspension: front: hub	1	62,000 mi
Traction control system	1	—
Visibility	1	—
Visibility/wiper	1	53,000 mi
Visibility: defroster/defogger/hvac system	1	9,000 mi
Visibility: defroster/defogger/hvac system: rear window	1	—
Visibility: rearview mirrors/devices: interior	1	182 mi
Visibility: sun/moon roof assembly	1	82,600 mi
Visibility: windshield wiper/washer	1	—

The 2003 model has 2 times as many complaints as this one. The 2005 model has roughly the same number of complaints as this one. These figures reflect raw complaint counts, not failure rates. Higher-selling model years naturally receive more complaints.

Safety recall repairs are provided free of charge by franchised dealers, regardless of vehicle age or mileage. This page displays aggregated data for the model year. To check recall status for a specific vehicle, search its VIN at nhtsa.gov.