NHTSA lists 9 safety recalls and 1,698 owner complaints for the 2004 Chevrolet Malibu. Most complaints involve steering (1,074) and electrical system (247). The EPA rates it 22–25 mpg combined.
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.
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.
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.
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Complaints for each Malibu model year we’ve synced.
| Model year | NHTSA complaints |
|---|---|
| 1997 | 452 |
| 1998 | 999 |
| 1999 | 800 |
| 2000 | 944 |
| 2001 | 739 |
| 2002 | 596 |
| 2003 | 611 |
| 2004 | 1,698 |
| 2005 | 1,393 |
| 2006 | 1,389 |
| 2007 | 992 |
| 2008 | 1,017 |
| 2009 | 1,511 |
| 2010 | 1,365 |
| 2011 | 978 |
| 2012 | 907 |
| 2013 | 924 |
| 2014 | 363 |
| 2015 | 270 |
| 2016 | 865 |
| 2017 | 727 |
| 2018 | 700 |
| 2019 | 193 |
| 2020 | 200 |
| 2021 | 90 |
| 2022 | 99 |
| 2023 | 73 |
| 2024 | 44 |
| 2025 | 12 |
“The contact owns a 2004 Chevrolet Malibu. The contact stated that while driving at 15 MPH, a whining noise was heard coming from the steering system when attempting to turn. The failure mileage was 133,000.”
“I was driving to work with my son and sister in the car when the steering wheel suddenly got very tight and started jerking when I attempted to make a left or right turn. I then stopped at a gas station and as soon as I came to a complete stop the vehicle shut off before I could turn it off manually. I then attempted to turn the key on and start the vehicle but it would not turn over, it would only make a clicking sound. I called a friend that was close by to come and assist me so when they arrived I asked them to jump my vehicle off via jumper cables which did get my vehicle's engine to finally start. The car sounded very weak as if it was going to shut off again once we disconnected the jumper cables but it didn't shut off. Nothing was working inside the car or outside meaning I had no radio, no interior lights and nothing on my dash was working. The speedometer wasn't working, the rims Guage wasn't working, the temp Guage wasn't working nor was anything else working on my dash. The turn signals were not working for either side and none of my headlights or taillights were working either. And I still did not safely have control of the steering. The only…”
“THE DRIVER SIDE SEAT THAT IS WELDED TO THE FRAME OF THE CAR HAS BROKE. THE RIGHT SIDE OF MY DRIVERS SIDE SEAT NOW COLLAPSES WHEN DRIVING WHICH IS EXTREMELY DANGEROUS NOT TO MENTION THE SEATBELT IS ATTACHED TO THE RIGHT SIDE OF THE SEAT AND BUCKLED INTO IT WHICH IS NOW COLLAPSED WHICH COULD CAUSE A MAJOR ISSUE IF I WAS TO EVER GET INTO AN ACCIDENT. I HAVE DONE SOME REASEARCH ONLINE AND THIS APPEARS TO BE A COMMON ISSUE AMONGSTS MOST 2004 MALIBU OWNERS. I AM THE SECOND OWNER AND I GET THE CAR IS CLOSE TO BEING 20 YEARS OLD BUT MINE ONLY HAS 60K MILES THE DRIVERS SEAT WELD SHOULD NOT JUST DETACH AND COLLAPSE WHILE DRIVING ON A PRACTICALLY BRAND NEW CAR. NOT TO MENTION I AM AN AVERAGE SIZED MAN 200 LBS 5 FOOT 7 ON TOP OF THAT I ENQUIRED TO FIX IT AT MY LOCAL CHEVROLET DEALER AND IT WILL COST WELL OVER 1000 DOLLARS BASED ON A VERBAL ESTIMATE. I CAN JERRY RIG THE SEAT TO NOT COLLAPSE BUT THAT DOESNT STOP THE FACT THAT GOD FORBID IM IN AN ACCIDENT MY DRIVERS SEAT COULD POTENTIALLY BECOME DETACHED HURLING MYSELF AND THE SEAT INTO THE WINDOW CAUSING SEVERE BODLY HARM OR WORSE DEATH. PLEASE LOOK INTO THIS AS IM SURE MANY OTHER PEOPLE HAVE THIS SAME PROBLEM IT IS A FAULTY…”
Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.
| Version | City | Hwy | Comb. | Fuel / yr | CO₂ g/mi |
|---|---|---|---|---|---|
| Malibu Auto 4-spd, 4 cyl, 2.2 L · Front-Wheel Drive | 21 | 31 | 25 | $2,500 | 355 |
| Malibu Auto 4-spd, 6 cyl, 3.5 L · Front-Wheel Drive | 20 | 29 | 23 | $2,700 | 386 |
| Malibu Maxx Auto 4-spd, 6 cyl, 3.5 L · Front-Wheel Drive | 19 | 28 | 22 | $2,850 | 404 |
| Item | Miles | Time | Note |
|---|---|---|---|
| Engine oil & filter | 5,000–10,000 mi | 6–12 months | Follow the oil-life monitor if fitted |
| Tire rotation | 5,000–7,500 mi | Every oil change | Check pressure monthly |
| Engine air filter | 15,000–30,000 mi | 1–2 years | Sooner in dusty areas |
| Cabin air filter | 15,000–25,000 mi | 1–2 years | |
| Brake fluid | — | 2–3 years | Absorbs moisture over time |
| Coolant | 60,000–100,000 mi | 5–10 years | Long-life coolants last longer |
| Spark plugs | 60,000–100,000 mi | — | Iridium/platinum plugs at the long end |
| 12V battery | — | 3–5 years | Heat shortens battery life |
9 safety recalls as of Nov 8, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.
Owners filed 1,698 complaints with NHTSA. The most-cited components are steering (1,074), electrical system (247), seats (163). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.
The EPA rates the 2004 Chevrolet Malibu at 22–25 mpg combined, depending on engine and drivetrain (3 versions rated).