2004 Chevrolet Malibu: Recalls, Problems & MPG
Here are the deets on the 2004 Chevrolet Malibu: 6 recalls, 1147 owner complaints and up to 25 mpg combined.
Recalls
6 vehicle recalls from the manufacturer, plus 3 equipment/tire recalls that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Equipment Vehicle recall #04V094000 · 2004 · 51,715 vehicles
What's wrong: 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…
Why it matters:
The 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.
Seat belts Vehicle recall #04V188000 · 2004 · 84,474 vehicles
What's wrong: 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.
Why it matters: If this occurred in a crash, the driver could receive greater injuries.
The 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.
Brakes (hydraulic) Vehicle recall #04V190000 · 2004 · 65,439 vehicles
What's wrong: 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.
Why it matters: 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.
The fix: Dealers will reprogram the ABS controller. Owner notification began on June 16, 2004. Owners should contact Chevrolet at 1-800-630-2438.
Steering Vehicle recall #14V153000 · 2014 · 1,373,177 vehicles
What's wrong: In the affected vehicles, there May be a sudden loss of electric power steering (eps) assist that could occur at any time while driving.
Why it matters: 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.
The 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…
Transmission & drivetrain, Transmission & drivetrain Vehicle recall #14V224000 · 2014 · 1,131,113 vehicles
What's wrong: 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…
Why it matters: 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…
The 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.
Stability control, Speed control / throttle Vehicle recall #14V252000 · 2014 · 2,440,524 vehicles
What's wrong: 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…
Why it matters: Any of the above failure conditions increases the risk of a crash.
The 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…
3 aftermarket equipment / tire recalls replacement parts sold to fit this car, not the car itself
Exterior lights Equipment recall #09E012000 · 2009 · 16,270 vehicles
What's wrong: 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.
Why it matters: Decreased lighting visibility May result in a vehicle crash.
The fix: Sabersport will notify owners and offer a full refund for the noncompliant combination lamps. The safety recall began on May 11, 2009.
Fuel system Equipment recall #11E009000 · 2011 · 4,887 vehicles
What's wrong: The defective fuel pump May seize, stopping the fuel flow to the engine creating a stalling condition.
Why it matters: A vehicle crash could occur should the engine stall while in use.
The 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.
Steering Equipment recall #14E044000 · 2014 · 7,304 vehicles
What's wrong: 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…
Why it matters: 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.
The 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.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 7 mention a fire, 22 injuries and 0 deaths were reported.
What owners describe
- Steering (798): the most common themes are steering problems (775), warning light on (184).
- Electrical (151): the most common themes are electrical failure (49), door / lock issues (29).
- Exterior lights (84): the most common themes are electrical failure (19), warning light on (11).
- Seats (69): the most common themes are electrical failure (5).
The 2004 Chevrolet Malibu has 1147 owner complaints, ranking #3 of 29 Malibu model years for complaints (1.7× the average Malibu year). Complaints peaked in 2014 (190 filed that year). The typical problem showed up when the car was about 7 years old, at a median of 78,500 miles. Neighboring years: 2003 (569 complaints, 2 recalls), 2005 (975 complaints, 3 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 2.2 L 4-cyl | Automatic 4-spd | Front-Wheel Drive | 21 | 31 | 25 | Regular |
| 3.5 L 6-cyl | Automatic 4-spd | Front-Wheel Drive | 20 | 29 | 23 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 2004 Chevrolet Malibu.
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Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
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FAQ
Does the 2004 Chevrolet Malibu have any recalls?
Yes. NHTSA lists 6 vehicle recalls for the 2004 Chevrolet Malibu, plus 3 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 2004 Chevrolet Malibu problems?
Owners have filed 1147 complaints with NHTSA. The most-reported areas are steering (798), electrical (151), exterior lights (84).
What gas mileage does the 2004 Chevrolet Malibu get?
EPA ratings run up to 25 mpg combined (2.2 L, Automatic 4-spd), across 2 engine and transmission combos.
Where can I get a 2004 Chevrolet Malibu repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.