Model year record

2004 Chevrolet Malibu Maxx recalls & problems

The 2004 Chevrolet Malibu Maxx has 3 safety recalls and 434 owner complaints on file with NHTSA. The most-reported problem area is steering (277 complaints).

Recalls3safety recalls

Complaints434filed by owners

Crashes · fires26 · 6reported in complaints

Injuries · deaths20 · 0reported in complaints

Safety recalls

Electronic stability control (esc)May 14, 2014

Electronic stability control (esc)

Recall 14V2520002,440,524 vehiclesopened after NHTSA action (ODI)

Problem: 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.

Components: Electronic stability control (esc); Vehicle speed control › Cruise control; Exterior lighting › Brake lights › Switch; Exterior lighting › Brake lights; Electrical system › Wiring

Power trainApr 30, 2014

Automatic transmission › Lever and linkage › Floor shift

Recall 14V2240001,131,113 vehiclesopened after NHTSA action (ODI)

Problem: 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 ÂPARKÂ position, the transmission may not be in ÂPARK.Â 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.

Components: Power train › Automatic transmission › Lever and linkage › Floor shift; Power train › Automatic transmission

SteeringMar 31, 2014

Electric power assist system

Recall 14V1530001,373,177 vehiclesopened after NHTSA action (ODI)

Problem: 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.

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.

Fuel economy

Malibu Maxx

22mpg combined

City / highway	19 / 28 mpg
Fuel	Regular Gasoline

3.5 L · 6 cyl · Automatic 4-spd · Front-Wheel Drive · about $3,050/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*
SteeringElectric power assist system; Hydraulic power assist system	277	17	1	12	70,000 mi
SeatsFront assembly › Seat heater/cooler; Front assembly › Power adjust	94	1	0	0	95,000 mi
Exterior lightingTurn signal; Headlights	39	1	4	1	70,000 mi
Electrical systemStarter assembly; Instrument cluster/panel	38	2	1	2	57,000 mi
Power trainAutomatic transmission	20	0	0	0	90,000 mi
Service brakes, hydraulicFoundation components › Disc › Rotor; Antilock/traction control/electronic limited slip	14	2	0	3	33,051 mi
Air bagsFrontal; Side/window	14	11	0	8	62,500 mi
Service brakes	8	1	1	0	77,500 mi
Fuel system, gasolineDelivery › Hoses, lines/piping, and fittings	7	0	1	0	101,143 mi
EquipmentElectrical › Anti-theft devices; Other › Owners/service/other manual	7	2	0	3	40,000 mi
Suspension	7	0	0	0	30,000 mi
Seat beltsFront › Anchorage	7	2	0	2	49,000 mi

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

Recent owner complaints

Air bags
The contact owns a 2004 Chevrolet Malibu Maxx. The contact stated that after he turned off and restarted the vehicle, the air bag warning light illuminated. The vehicle was taken to Bruceâs auto body shop where it was diagnosed that the air bag side impact sensor failed to reset and needed to be replaced. The vehicle was not repaired. The manufacturer was notified by the dealer and the contact was informed that the parts were no longer being manufactured and was unavailable. The failure mileage was approximately 164,000.
Jan 18, 2023 · 164,000 miles
Steering
The contact owns a 2004 Chevrolet Malibu. The contact stated while driving 50 MPH, the vehicle experienced a loss of power steering assist. The contact related the failure to NHTSA Campaign Number: 14E044000 (Steering) however, the VIN was not included. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 160,000.
May 9, 2022 · 160,000 miles
Steering › Hydraulic power assist › Power steering fluid
The contact owns a 2004 Chevrolet Malibu Maxx. The contact stated while driving approximately 30 MPH, the vehicle lost power steering functionality. The power steering warning light was illuminated. The vehicle was taken to an independent mechanic and diagnosed with power steering failure. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 117,000.
May 1, 2022 · 117,000 miles
Power train
TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. THE CONTACT STATED THAT WHILE MAKING A LEFT TURN THE VEHICLE SHIFTED INTO NEUTRAL INDEPENDENTLY WITHOUT WARNING. THE CONTACT DEPRESSED THE BRAKE PEDAL TO STOP THE VEHICLE. THE CONTACT ATTEMPTED TO MANUALLY SHIFT THE VEHICLE INTO PARK HOWEVER, THE TRANSMISSION FAILED TO ENGAGE. THE CONTACT PUSHED THE VEHICLE OVER TO THE SIDE OF THE ROADWAY. THE VEHICLE WAS TOWED TO MIDWAY CHEVROLET (2323 W BELL RD, PHOENIX, AZ) WHERE IT WAS DIAGNOSED AND DETERMINED THAT THE TRANSMISSION FAILED AND NEEDED TO BE REPLACED. THE CONTACT MENTIONED NHTSA CAMPAIGN NUMBER: 14V224000 (POWER TRAIN) AS A POSSIBLE SOLUTION TO THE FAILURE, HOWEVER THE VIN WAS NOT…
Apr 10, 2018 · 100,000 miles
Steering
TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. WHILE DRIVING APPROXIMATELY 60 MPH, THE STEERING ABILITY SEIZED AND ALL THE WARNING INDICATORS ILLUMINATED. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD AS THE POWER STEERING WARNING INDICATOR REMAINED ILLUMINATED. THE VEHICLE WAS DRIVEN TO THE CONTACT'S RESIDENCE AND THEN TO MCCURLEY CHEVROLET (1325 N AUTOPLEX WAY, PASCO, WA 99301) WHERE IT WAS DETERMINED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 14V153000 (STEERING). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.
May 20, 2019 · 100,000 miles
Steering
TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. WHILE OPERATING THE VEHICLE, THE POWER STEERING MALFUNCTIONED AND THE STEERING WHEEL BECAME VERY DIFFICULT TO TURN IN EITHER DIRECTION. ALSO, 'POWER STEERING' DISPLAYED ON THE INSTRUMENT PANEL. THE VEHICLE WAS DRIVEN TO BILLION AUTOMOTIVE (600 W. 41ST, SIOUX FALLS, SD) WHERE IT WAS DIAGNOSED THAT THE TORQUE SENSOR WAS FAULTY AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE BUT NO ASSISTANCE WAS OFFERED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 125,000.
May 1, 2019 · 125,000 miles
Electronic stability control (esc)
NO STEERING,STEERING TURNS AROUND AND AROUND WITHOUT STOP TURNING IN EITHER DIRECTION,RIGHT OR LEFT. SECOND TIME THIS HAPPENED,SPENT APPROXIMATELY $1200.00 BEFORE. CAR THIS TIME ENDED IN A TOW POUND YARD. TRIPLE AAA MOVED MY CAR TO A SHOP CALLED QUICK STOP WHERE I WANTED TO GET MY CAR FIXED AT ONLY TO DISCOVER THEY DIDN'T DO ELECTRICAL WORK WHICH THEY DISCOVERED WAS THE PROBLEM AMONG OTHERS. AGAIN THE TOWING COMPANY TRIPLE AAA CARRIED IT TO WEBB CHEVROLET SUGGESTED BY THIS SHOP. WEBB CHEVROLET DISCOVERED ALSO ELECTRICAL ISSUES. MY INSURANCE NOTIFIED ME AFTER I CONTACT THEM FOR A CLAIM REPORT. AN ESTIMATOR WAS SENT TO WEBB CHEVROLET ALSO THEY DISCOVERED AFTER A TEAR DOWN DIAGNOSIS THAT IT IS…
Mar 7, 2019 · 155,000 miles
Engine
STEERING OUT OF WHACK. I HAVE HAD MY CONTROL ARM ON BOTH SIDES CHANGED ALONG WITH AXLES AND A ALIGNMENT. NO LUCK ITS STILL ALL OVER ROAD. I DRIVE FROM SYLVESTER GA TO TIFTON GA EVERYDAY. IT DOES THE SAME THING EVERYTIME. ALSO I HAVE HAD MY LIGHTS REPLACED 3 TIMES IN THE LAST YEAR. WHY ARENT THE LASTING. GAS CAP KEEPS READING ERROR. WHOLE CAR. I CAN LET SOMEONE DRIVE IT TO SEE WHAT I AM SAYING.
Jan 1, 2019 · 140,000 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.

NHTSA defect investigations

Turn Signal LampsClosed
GM designed the MY 2004 and 2005 Chevrolet Malibu and Malibu Maxx vehicles with a daytime running lamp (DRL) system that uses the same filament (the high power filament of a dual filament bulb) as the front turn signals.The high power filament operates at full battery voltage when functioning as a DRL.The DRL is illuminated whenever the headlamps are off, increasing the duty cycle of the front turn signal bulb.The MY 2003 and earlier Malibu vehicles (Malibu Maxx was not manufactured for sale in the U.S. prior to MY 2004) used a headlamp based design, operated at a reduced voltage, for the DRL function; GM reverted back to this design on the MY 2006 and later Malibu and Malibu Maxx vehicles. Filament based bulbs have a finite life (hours of illumination) for any given operating voltage.As a result, increasing the duty cycle of a bulb typically decreases the life span of the bulb.GM…
EA09004 · opened Mar 20, 2009 · closed Aug 12, 2010
TURN SIGNAL LAMPSClosed
THE SUBJECT VEHICLES MAY EXPERIENCE LOSS OF FUNCTION OF ONE OR MORE OF THE PARK, TURN, STOP OR DAYTIME RUNNING LAMPS (DRL).FAILURE OF THE BULB MAY ALSO INCLUDE DISCOLORATION (HEAT DAMAGE) TO THE BULB SOCKET.GENERAL MOTORS (GM) TECHNICAL SERVICE BULLETIN (TSB) NUMBER 06-08-42-004C INSTRUCTS TECHNICIANS TO EXAMINE THE LAMP HOUSING FOR SIGNS OF DISCOLORATION AND TO REPLACE THE BULBS AND OR SOCKETS DEPENDING ON THE SEVERITY OF THE DISCOLORATION AND THE CONDITION OF THE BULBS AND SOCKETS.THE SCOPE OF INVESTIGATION IN THE PRELIMINARY EVALUATION (PE08-062) WAS THE 2004 MALIBU/MAXX.HOWEVER, THE AGENCY EVALUATED GM'S WARRANTY DATA WHICH INDICATES THAT THE 2005 MODEL YEAR (MY) MALIBU AND MALIBU MAXX VEHICLES ARE ALSO AFFECTED BY THIS CONDITION.THIS INVESTIGATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA09-004).
PE08062 · opened Oct 21, 2008 · closed Mar 20, 2009
LOSS OF ELECTRIC POWER STEERINGClosed
IN PERFORMING THIS ENGINEERING ANALYSIS, ODI DETERMINED THAT THE ELECTRIC POWER STEERING SYSTEM IN THE SUBJECT VEHICLES CAN MALFUNCTION OR FAIL, CAUSING THE DRIVER TO LOSE POWER STEERING ASSISTANCE; HOWEVER, DUE TO THE FOLLOWING REASONS, ODI HAS DECIDED THAT FURTHER EXPENDITURE OF AGENCY RESOURCES ON THIS INVESTIGATION IS NOT WARRANTED AT THIS TIME: - GM ISSUED CUSTOMER SATISFACTION CAMPAIGN (CSC) 04050A INDECEMBER 2004 TO ADDRESS THE ALLEGED DEFECT IN APPROXIMATELY58,700 SUBJECT VEHICLES, ENCOMPASSING AT LEAST 97 PERCENT OF THECOMPLAINT AND WARRANTY CLAIMS POPULATION.VEHICLES OUTSIDE THECSC 04050A POPULATION CONTAIN A NEWLY DESIGNED TORQUE ANDPOSITION SENSOR AND HAVE EXPERIENCED A RELATIVELY LOW COMPLAINTRATE.THIS CUSTOMER SATISFACTION CAMPAIGN PRESENTLY HAS ACOMPLETION RATE OF 52%. - THE IMPACT ON THE DRIVER?S ABILITY TO CONTROL THESE RELATIVELYSMALL AND LIGHT VEHICLES WAS…
EA04018 · opened Jul 1, 2004 · closed May 10, 2005
LOSS OF ELECTRIC POWER STEERINGClosed
ODI OPENED PE04-031 BASED ON EIGHT REPORTS OF ALLEGED POWER STEERING FAILURE IN THE SUBJECT VEHICLES.THE COMPLAINTS ALLEGE THAT THE DRIVER SUDDENLY LOST ALL ELECTRIC POWER STEERING ASSISTANCE WITHOUT WARNING MAKING THE VEHICLE DIFFICULT TO STEER. THE SUBJECT VEHICLE UTILIZES AN ELECTRIC POWER STEERING ASSIST SYSTEM (EPS) THAT PROVIDES VARIABLE STEERING ASSISTANCE BASED ON STEERING WHEEL TORQUE, STEERING WHEEL POSTION, AND VEHICLE SPEED.GENERAL MOTORS DOCUMENTS IDENTIFIED THE FOLLOWING TWO FACTORS THAT CONTRIBUTED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES: A.CONTAMINATION OF THE TORQUE AND POSITION SENSOR FROM THESEPARATION OF GREASE APPLIED TO THE STEERING COLUMN ASSEMBLY. B.ELECTRICAL NOISE GENERATED ON THE POWER AND GROUND SLIP RING SURFACES OF THE TORQUE AND POSITION SENSOR.THE NOISE IS GENERATED AS THE SENSOR CONTACT BRUSHES MOVE ALONG THE SLIP RING SURFACES WHEN THE STEERING…
PE04031 · opened Mar 30, 2004 · closed Jul 1, 2004