Problems · NHTSA complaints

2004 Volkswagen Passat problems

Owners filed 283 complaints about the 2004 Volkswagen Passat with NHTSA between Jan 2004 and Aug 2025. The most-cited component is engine and engine cooling (59).

Complaints
283
Filed with NHTSA
Crashes
9
Reported by owners
Fires
25
Reported by owners
Injuries
23
People reported injured
Deaths
0
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Engine and engine cooling59
  2. Power train38
  3. Seats34
  4. Fuel system, gasoline28
  5. Fuel/propulsion system25
  6. Electrical system24
  7. Engine18
  8. Exterior lighting17
  9. Structure16
  10. Visibility13
  11. Service brakes, hydraulic12
  12. Air bags9
  13. Tires8
  14. Vehicle speed control7

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Nov 10, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
200431
200519
200620
200729
200832
200931
201027
201114
20129
201313
201419
20158
20168
20175
20188
20193
20202
20213
20220
20230
20240
20252

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Engine and engine cooling

59 reports5 fires1 related recall
“POSSIBLE CAM TENSIONER THAT CAUSES THE CAR TO MAKE A LOUD CLICKING NOISE AND THE CHECK ENGINE LIGHT IS ON AS A RESULT. TOOK IT TO 3 MECHANICS AND DID A DIAGNOSTIC BUT COULD NOT FIND THE PROBLEM. HELP ME PLEASE! *TR”
Owner complaint to NHTSAFiled Aug 22, 2014Engine and engine coolingODI 10627448

Power train

38 reports1 crash
“POWER TRAIN ISSUE: BAD TORQUE CONVERTER (TC). WHY A SAFETY ISSUE? IT CAN FAIL WHILE ON THE HIGHWAY SENDING DEBRIS INTO THE TRANSMISSION CAUSING A CATASTROPHIC FAILURE. CAUSED BY A BAD SEAL GASKET. TECHNICAL BULLETIN # 2011908 ADDRESS THE ISSUE IN 2007. BUT THE TDIS WERE NOT INCLUDED IN THE TB [SAME TC & TRANSMISSION], AND THIS IS A VERY COMMON PROBLEM IN MANY VW, AUDI AND BMW VEHICLES, INCLUDING TDIS. E.G. VW & AUDI: HTTP://KANSASCITYTDI.COM/AUDIPASSAT-P0741-17125-CODE/ BMW: HTTP://FORUMS.BIMMERFORUMS.COM/FORUM/SHOWTHREAD.PHP?T=1601642 WITH A P0741 ERROR: DTC RESULTS: 17125 P0741 003 TORQUE CONVERTER CLUTCH CIRC. PERFORMANCE OR STUCK OFF INTERMITTENT IF YOU DO A WEB SEARCH FOR: P0741 ERROR CODE TRANSMISSION TORQUE CONVERTER THE RESULTS ARE STARTLING, IT SEEMS THAT VW, AUDI AND BMW ALL HAVE THE SAME ISSUE WITH TCS, "MY UNDERSTANDING IS THE INTERNAL TC SEALS WERE NOT UP TO THE TASK ON THE ORIGINAL TCS OF THAT ERA. ...INCLUDING AUDI". HTTP://FORUMS.TDICLUB.COM/SHOWPOST.PHP?P=3036384&POSTCOUNT=5 "IF THE PROBLEM IS NOT ADDRESSED THEN THE TRANSMISSION WILL OVER HEAT DUE TO THE SLIPPAGE AND YOU WILL NEED TO REPLACE THE TRANSMISSION."…”
Owner complaint to NHTSAFiled Nov 19, 2012Power train, StructureODI 10485111

Seats

34 reports13 fires
“A COIL FOR HEATED SEATS HAS MELTED A HOLE IN THE DRIVER'S SIDE SEAT. THIS CAUSED PAIN AND CONFUSION WHILE DRIVING ON THE HIGHWAY. THE SEAT NOW HAS AN UGLY MELTED HOLE IN IT.”
Owner complaint to NHTSAFiled Feb 11, 2021SeatsODI 11395719

Fuel system, gasoline

28 reports2 fires1 related recall
“The contact owns a 2004 Volkswagen Passat. The contact stated that there was gasoline leaking in his driveway where the vehicle was parked, after he had refueled the vehicle the day before. The vehicle was taken to an independent mechanic and the mechanic informed the contact that it was a known failure related to NHTSA Campaign Number: 08V156000 (Fuel System, Gasoline). The dealer and manufacturer were made aware of the failure but informed the contact that the failure was addressed in 2012 and the recall was closed on the VIN. The failure mileage was 97,361.”
Owner complaint to NHTSAFiled Sep 20, 2021Fuel system, gasolineODI 11433670

Fuel/propulsion system

25 reports
“A fuel leak has developed from the top side of the fuel tank on the drivers side of me vehicle. A fuel leak in this manner is a serious critical and immediate safety risk. Recall 08V156000 was 'performed' on my vehicle back in 2008 but the exact same fuel system safety defect has returned. VW acknowledges the recall and claims it was completed while only an inspection to check for fuel leaks was performed at the time. VW Care and my local dealership refuse to address the ongoing issue. This poses a continued fire risk, and I am now being told to pay out of pocket for a known safety recall that clearly failed to remedy the original defect.”
Owner complaint to NHTSAFiled Aug 1, 2025Fuel/propulsion systemODI 11677910

Electrical system

24 reports7 fires
“HAD TO REPLACE THE COMFORT CONTROL MODULE ALONG WITH UNTOLD AMOUNT OF WIRES DUE TO WATER DAMAGE. AFTER BEING PARKED AND TURNED OFF THE WINDOWS ROLL. DOWN THE ALARM IS DISABLED, THE DOORS UNLOCK. WHILE DRIVING LIGHTS GO. ON AND OFF DOORS LOCK AND UNLOCK EMERGENCY FLASHERS GO OFF AND ALARM WILL GO OFF. CAN'T UNLOCK CAR WITHOUT SETTING ALARM OFF.”
Owner complaint to NHTSAFiled Mar 6, 2019Electrical system, Exterior lighting, Vehicle speed controlODI 11184655
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.