Model year record

2004 Chevrolet Cavalier recalls & problems

The 2004 Chevrolet Cavalier has 2 safety recalls and 330 owner complaints on file with NHTSA. The most-reported problem area is electrical system (192 complaints).

Recalls2safety recalls

Complaints330filed by owners

Crashes · fires17 · 6reported in complaints

Injuries · deaths19 · 1reported in complaints

2004 Chevrolet Cavalier in an NHTSA crash test — NHTSA crash test

Safety recalls

SteeringOct 17, 2008

Steering

Recall 08E0630003,855 vehicles

Problem: DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057, 7-3058, 7-3059 (SOLD UNDER THE "NAPA" BRAND NAME), AND PLATINUM PARTS #'S 2425151, 2425152, AND 2425153 MANUFACTURED DURING THE MONTH OF SEPTEMBER 2007. THESE REPLACEMENT STEERING SHAFTS CAN BE USED ON THE VEHICLES LISTED ABOVE. THE WELD CONNECTING THE INNER TUBE TO THE OUTER TUBE MAY BE DEFECTIVE.
Risk: IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.
Fix: DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 16, 2008. OWNERS MAY CONTACT DORMAN TOLL FREE AT 1-800-523-2492.

Seat beltsJun 23, 2004

Rear/other

Recall 04V30000037 vehicles

Problem: CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, 'SEAT BELT ASSEMBLY ANCHORAGES.' THE PASSENGER-SIDE REAR SAFETY BELT MAY HAVE BEEN INSTALLED WITH AN INCORRECT NUT AND BOLT.
Risk: IN A SEVERE CRASH, THE UPPER SEAT BELT ANCHORAGE MAY SEPARATE. THE EFFECTIVENESS OF THE SEAT BELT COULD THEN BE REDUCED AND THE OCCUPANT COULD RECEIVE GREATER INJURIES.
Fix: DEALERS ARE TO INSPECT THE SAFETY BELT ANCHORAGE AND INSTALL A NEW NUT AND BOLT, IF NECESSARY. THE RECALL BEGAN ON AUGUST 23, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 AND PONTIAC AT 1-800-620-7668.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Chevrolet Cavalier 4-DR.

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2004 Chevrolet Cavalier 2-DR.

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Cavalier

27mpg combined

City / highway	23 / 33 mpg
Fuel	Regular Gasoline

2.2 L · 4 cyl · Manual 5-spd · Front-Wheel Drive · about $2,500/year to fuel

Cavalier

25mpg combined

City / highway	21 / 31 mpg
Fuel	Regular Gasoline

2.2 L · 4 cyl · Automatic 4-spd · Front-Wheel Drive · about $2,700/year to fuel

Cavalier Dual-fuel Bifuel (CNG)

24mpg combined

City / highway	21 / 29 mpg
Fuel	Regular Gasoline

2.2 L · 4 cyl · Automatic 4-spd · Front-Wheel Drive · about $2,800/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Electrical systemInstrument cluster/panel; Wiring › Interior/under dash	192	2	5	2	54,450 mi
Vehicle speed controlAccelerator pedal; Cruise control	27	0	0	0	58,000 mi
Power trainManual transmission; Clutch assembly	24	2	0	0	43,500 mi
VisibilityPower window devices and controls; Glass, side/rear	23	1	0	0	39,000 mi
SteeringHydraulic power assist › Hose, piping, and connections; Rack and pinion	16	1	0	0	130,012 mi
Engine and engine coolingEngine	15	1	1	1	30,000 mi
Service brakes, hydraulicPedals and linkages; Foundation components › Disc › Pads	15	1	0	1	33,250 mi
Air bagsFrontal; Frontal › Sensor/control module	15	10	0	12	50,000 mi
StructureBody; Body › Trunk lid	13	0	1	0	51,543 mi
Unknown or other	13	0	0	0	40,000 mi
Fuel system, gasolineStorage › Tank assembly › Filler pipe and cap	9	1	0	3	78,000 mi
SeatsMid/rear assembly; Front assembly › Recliner	8	2	0	4	45,000 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Steering
The whole steering column is loose The pins are all backed out Iâm afraid to drive it I think this is a manufactured design flaw
May 17, 2020
Suspension
The vehicle failed to pass pa. state inspection due to a severely rusted frame over the rear axles. The estimate to repair the frame was @$3000.
Apr 1, 2021
Suspension
The contact owns a 2004 Chevrolet Cavalier. The contact stated while driving 10 MPH, the front driverâs side tire had detached. The vehicle was towed to the contact's residence. An independent mechanic went to the contact's residence and diagnosed that the lower control arm rusted and detached from the subframe. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 200,000.
Aug 1, 2021 · 200,000 miles
Power train
IN THE PARKING LOT WHERE I WORK MY CAR WOULD NOT START. WHEN MOVING THE AUTOMATIC TRANSMISSION LEVER IT DID NOT CATCH ON TO ANYTHING. THE CAR JUST ROLLED BACKWARDS AND I HAD TO IMMEDIATELY PRESS ON THE BRAKES PREVENTING AN ACCIDENT. MY CAR HAD TO BE TOWED TO THE AUTO SHOP. DIAGNOSIS: SHIFTER CABLE WAS DETACHED FROM TRANSMISSION. PREVIOUSLY ON 09/13/2011 THE SAME THING HAPPENED TO MY CAR. THE SHIFTER CABLE BROKE AND I HAD TO BE TOWED TO LOU BACHRODT CHEVROLET BOTH TIMES. THE 2ND TIME INVOICE NO. CWCS692729 $502.24 AND $477.55 INVOICE NO.CWCS149491 THE FIRST TIME. THIS CAR SHOULD BE RECALLED. TWO TIMES IS TOO MANY.
Dec 3, 2020 · 85,509 miles
Seat belts
CAN'T SAFELY INSTALL A CAR SEAT BECAUSE THE SAFETY BELTS DO NOT PROPERLY RETRACT. THEREFORE THE CAR SEAT IS NOT STABLE. THE VEHICLE WAS STATIONARY.
Mar 6, 2020 · 49,000 miles
Vehicle speed control
WHEN I'M DRIVEN ABOUT 25 MILES THE ACCELERATOR STAYS STUCK AND THE SPEED KEEP GOIN UP IF YOU DON'T PUT THE BRAKES
Nov 13, 2019 · 11,000 miles
Air bags
AIRBAG LIGHT COMES ON AT RANDOM INTERVALS FOR ABOUT 5 SECONDS, THEN TURNS OFF. SPEED, ROAD CONDITIONS, AND GEAR MAKE NO DIFFERENCE AS TO WHEN IT COMES ON. IT HAS COME ON WHILE TURNING, WHILE DRIVING IN TOWN AT 20 MPH, WHILE AT A COMPLETE STOP, WHILE GOING OVER A BUMP, AND WHILE GOING 50MPH ON THE HIGHWAY.
Oct 29, 2019 · 165,700 miles
Steering
EVERY TIME I GO TO MY JOB MY POWER STEERING RESERVOIR BECOMES EMPTY AFTER I PUT ONE OR MORE QUARTS IN THE RESERVOIR. ANYTIME I DRIVE AT HIGHWAY SPEEDS I SWAY BACK AND FORTH NO MATTER HOW MUCH CONTROL I HAVE OVER THE VEHICLE. MY STEERING GETS SO HARD TO THE POINT WHERE I ALMOST CRASH EVERY TIME I DRIVE MY CAR ANYWHERE BECAUSE I HAVE NO POWER STEERING OR DON'T HAVE A LOT OF CONTROL OVER THE STEERING BECAUSE IT BECOMES SO TIGHT.
May 28, 2019 · 166,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.