Data sourced from NHTSA public database. For informational purposes only. Always consult a qualified mechanic.
2004 Chevrolet Malibu — Known Issues & Recalls
Complaints from Jan 2015 to Dec 2013
The most reported issue is steering problems (870 complaints). 81 complaints involved crashes. 15 involved fires.
Open Safety Recalls (9)
NHTSA Campaign: 14V252000
Component: ELECTRICAL SYSTEM:WIRING
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.
Risk: Any of the above failure conditions increases the risk of a crash.
Fix: 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.
NHTSA Campaign: 14V153000
Component: STEERING:ELECTRIC POWER ASSIST SYSTEM
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.
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.
Fix: 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.
NHTSA Campaign: 14V224000
Component: POWER TRAIN:AUTOMATIC TRANSMISSION
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.
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.
Fix: 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.
NHTSA Campaign: 14E044000
Component: STEERING
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.
Risk: 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.
Fix: 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.
NHTSA Campaign: 11E009000
Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
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.
Risk: A VEHICLE CRASH COULD OCCUR SHOULD THE ENGINE STALL WHILE IN USE.
Fix: 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.
NHTSA Campaign: 09E012000
Component: EXTERIOR LIGHTING
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.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: 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.
NHTSA Campaign: 04V190000
Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE
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.
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.
Fix: DEALERS WILL REPROGRAM THE ABS CONTROLLER. OWNER NOTIFICATION BEGAN ON JUNE 16, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438.
NHTSA Campaign: 04V188000
Component: SEAT BELTS:FRONT:ANCHORAGE
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.
Risk: IF THIS OCCURRED IN A CRASH, THE DRIVER COULD RECEIVE GREATER INJURIES.
Fix: 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.
NHTSA Campaign: 04V094000
Component: EQUIPMENT:OTHER:LABELS
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.
Fix: 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-Reported Issues (20 of 1697)
Steering →13 issues
Your car's electric power steering has failed, and a warning message appears on the dashboard. Without power steering assistance, turning the wheel becomes extremely difficult, especially in snow or emergency situations where you need to swerve to avoid a collision. This creates a serious safety risk in winter driving conditions. The fix will likely involve diagnosing and repairing or replacing the electric power steering motor or control system.
Parts you may need:
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Your steering wheel has locked up multiple times while driving at slow speeds and parallel parking, leaving you unable to turn the car. This is a serious safety hazard that has happened repeatedly. The power steering system may need inspection and repair to restore normal steering control.
Parts you may need:
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Your power steering intermittently stops working while you're driving, forcing you to pull over, shut off the engine, and restart it to regain steering control. This happens at all speeds—from parking lots to highways—and is identical to a problem that was recalled and fixed in 2014 under recall 14116. The issue may require diagnosis of the power steering system, potentially including the pump, hoses, or electronic control components.
Parts you may need:
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Your power steering suddenly lost assist, making it very difficult to steer the car safely. A dealer confirmed the problem and found a fault code ($185 inspection fee). Although your car was recalled under Bulletin 14-116 to fix this exact issue, the problem returned after the recall work was completed. The fix likely involves replacing or reprogramming the electric power steering control module or related electrical components.
Parts you may need:
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Your car's steering becomes overly sensitive at highway speeds, where even a light touch on the steering wheel causes the car to swerve significantly. There are no warning lights or messages to alert you to the problem. This unpredictable steering response at higher speeds could make the car difficult to control.
Parts you may need:
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Your car's dashboard is displaying a power steering failure warning message. A mechanic checked your vehicle but couldn't find a stored error code to explain why the warning appeared. Your steering system may be experiencing an electrical or fluid issue that's triggering the warning light. A dealership diagnostic scan and possible power steering fluid check or electrical system inspection will likely be needed to identify the root cause.
Parts you may need:
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Your car's power steering suddenly stopped working while driving at various speeds, making the steering wheel much harder to turn. At the same time, warning lights appeared on your dashboard for oil and theft, along with a message saying "Service Power Steering." The problem occurred around 100,000 miles and wasn't diagnosed or repaired.
Parts you may need:
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While driving at 50 mph, your power steering suddenly stopped working, making the steering wheel much harder to turn. This happened at around 160,000 miles on your 2004 Chevrolet Malibu. The issue may be related to a known steering problem that Chevrolet has issued a recall for (Campaign 14E044000). You'll need to have a mechanic inspect the power steering system to identify and repair the underlying cause.
Parts you may need:
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Your power steering suddenly stopped working while your teenager was driving, making the steering wheel very hard to turn even though the vehicle remained drivable. A steering warning light came on at the time. You discovered that your vehicle had an open recall from 2014 that was never actually completed, despite showing as finished in the system, and the original parts were never replaced. The repair will likely involve replacing the faulty power steering components that should have been replaced under the recall.
Parts you may need:
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Your car is losing power steering assistance again when turning corners, even though a steering recall was completed in March 2015. A power steering warning code appeared, which a shop cleared, but the problem persists. The power steering system may need inspection or replacement of internal components.
Parts you may need:
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Your power steering suddenly stopped working while you were backing up. The dealer identified that your steering shaft needs to be replaced. Since your vehicle has 139,000 miles and is out of warranty, you'll need to pay for the repair yourself. The fix will involve replacing the steering shaft assembly.
Parts you may need:
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While driving at about 30 mph, your power steering suddenly stopped working and the power steering warning light came on. A mechanic confirmed the power steering system had failed. Without power steering, your car becomes much harder to steer and control.
Parts you may need:
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Your car's electric power steering system has failed, and a warning message appeared on your dashboard. You're experiencing difficulty steering the vehicle because power assist is no longer working. The repair will likely involve diagnosing and replacing the electric power steering motor or control module.
Parts you may need:
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Vehicle Speed Control,service Brakes,air Bags →1 issue
Your Malibu was involved in a crash where it hit another vehicle on the driver's side, causing that vehicle to tip onto two wheels. The other driver sustained neck injuries. This complaint suggests potential issues with your Malibu's speed control or braking that may have contributed to the accident, though specific details are limited. A thorough inspection of your braking system and speed control components would be recommended to ensure they're functioning properly.
Parts you may need:
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Air Bags →1 issue
Your airbag warning light turned on after you restarted your Malibu. A shop diagnosed that the side impact sensor failed to reset and needs replacement. However, Chevrolet has discontinued this part and it's no longer available, so the repair cannot be completed.
Parts you may need:
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Steering,electrical System,exterior Lighting →1 issue
While driving, your steering wheel suddenly became very stiff and jerked when turning, then your car shut off unexpectedly at a gas station and wouldn't restart—it only clicked. After a jump start, the engine ran weakly but the car had no electrical power: your dashboard gauges, radio, interior lights, turn signals, headlights, and taillights all stopped working, and your steering remained difficult to control. A warning light showing a locked vehicle symbol appeared after the jump start. This suggests a serious electrical system failure affecting power distribution throughout the vehicle.
Parts you may need:
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Steering,vehicle Speed Control →1 issue
Your power steering failed again after being repaired under a 2014 recall, and this time you were charged $1,400 instead of having it covered. Additionally, your cruise control stopped working over a year ago, and you weren't informed of any available recall. The power steering issue likely requires replacement of the steering pump or related hydraulic components, while the cruise control may need a control module or wiring repair.
Parts you may need:
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Latches/locks/linkages,engine →1 issue
Your car stalled at a red light and made strange noises from the dashboard. When you tried to restart it, the door locks started locking and unlocking on their own. You were able to get it running again and took it to a locksmith, who confirmed the ignition switch was fine. The dealer acknowledged the problem but said they couldn't fix it, and the issue was never diagnosed or repaired.
Parts you may need:
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Exterior Lighting →1 issue
Both of your front headlights are dimming in both low and high beam modes and eventually burning out. When you inspected the headlights, you found that the bulb sockets had melted, likely due to faulty wiring in the headlight assembly causing excessive heat. Even after replacing the sockets with aftermarket parts, the problem came back, suggesting the underlying wiring issue wasn't resolved. The fix will likely involve inspecting and repairing or replacing the wiring harness and possibly the entire headlight assembly.
Parts you may need:
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Steering,electrical System →1 issue
Your power steering suddenly stopped working while backing out of your driveway, and your dashboard lights went out at the same time. The steering wheel became extremely hard to turn, but power steering returned to normal after you restarted the engine. While this has only happened once so far, losing power steering at highway speeds could be dangerous. A mechanic recommended taking the car to a dealership, as they have specialized diagnostic equipment to pinpoint whether the issue is electrical or mechanical.
Parts you may need:
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