2004 Chevrolet Malibu complaints

POWER STEERING WAS REPLACED BACK IN 2005, AS OF TODAY CAR IS BACK IN SHOP FOR THE SAME PROBLEM SUPPOSEDLY THAT WAS FIXED IN 2005. 1) LIGHT COMES ON "POWER STEERING" 2) CAR IS HARD TO STEER (THIS PROBLEM HAPPENED RIGHT ON THE HIGHWAY AND I WAS VERY SCARED FOR MY LIFE AS TO NO OTHER WARNING BUT THE LIGHT COMING ON AND IMMEDIATELY BEING UNABLE TO TURN). 3) CURRENTLY THE CAR IS IN THE SHOP. *JB

POWER STEERING LIGHT REPEATEDLY GOING ON AND OFF,STEERING GETTING TIGHT OFF AND ON,WENT TO MECHANIC THEY RESET LIGHT, POWER STEERING LIGHT OFF AND ON YET AGAIN, THEN HE HAD LOST POWER STEERING 3 X,BUT IF HE WAS ABLE TO PULL OVER SHUT OFF AND RESTART, HE COULD DRIVE FOR A WHILE, FINALLY GOT IT TO CHEVROLET THEY HAD IT 2 DAYS, REPLACED STEERING COLUMN $796.00, NO WARRANTY NO RECALL, ONLY A SERVICE BULLETIN OUT ABOUT THE PROBLEM, WHICH WHEN I TALKED TO GM THEY SAID THEY HAVE HAD NO COMPLAINTS! ARE THEY WAITING FOR DEAD BODIES TO START PILING UP BEFORE THEY SEND OUT A RECALL? *TR

BOUGHT 6 CYLINDER 2004 MALIBU WITH 2000 MILES FROM DEALER. WITHIN TWO MONTHS, STEERING FAILED. STEERING COLUMN WAS REPLACED. SINCE THEN STEERING COLUMN HAS BEEN REPLACED A TOTAL OF FOUR TIMES FOR CONTINUED "CLUNKING" NOISE IN FRONT STEERING AREA. LAST TIME CAR WAS STILL IN WARRANTY. CAR NOW HAS 62,000 MILES AND CONTINUES TO CLUNK JUST AS WHEN NEW AND AS EACH COLUMN WAS REPLACED. *JB

ON SATURDAY, AUGUST 18, 2007 MY WIFE AND I WERE TRAVELING AT 60 MPH ALONG A WINDY, HILLY STRETCH OF ROAD. AT THE TOP OF THE THIRD HILL, THE TRANSMISSION DROPPED TO ZERO. AFTER COASTING DOWN THE HILL, I WAS ABLE TO CONTINUE IN FIRST GEAR ONLY. AFTER STOPPING FOR 15 MINUTES, I WAS ABLE TO CONTINUE DRIVING IN LOW GEARS. HOWEVER, IF I TRIED TO ACCELERATE QUICKLY (SUCH AS TO MERGE WITH INTERSTATE TRAFFIC, OR TO MAKE A LEGAL U-TURN) THEN THE TRANSMISSION FAILED AGAIN. ON SUNDAY, AUGUST 19, I TOOK THE VEHICLE TO A SERVICE STATION AND HAD THE TRANSMISSION FLUSHED AND FILLED. MY HOPE WAS TO AVOID ANY MECHANICAL PROBLEMS. HOWEVER, THIS SERVICE DID NOT RESOLVE THE PROBLEM. ON TUESDAY, AUGUST 21, I TOOK THE VEHICLE TO MY LOCAL CHEVY DEALER WHO TOLD ME THE CLUTCH WAS COMPLETELY BURNED OUT. THEY ASKED ME WHY I WAITED SO LONG TO HAVE THE TRANSMISSION SERVICED. I POINTED OUT TO THEM THAT THE OWNER'S MANUAL STATES THAT IT IS A "MAINTENANCE FREE" TRANSMISSION THAT SHOULD NEVER NEED SERVICING. *TR

I OWN A 2004 MALIBU SEDAN LT (80K) AND A 2004 MALIBU MAXX LT (50K). BOTH CARS HAVE THE CLUNKING NOISE IN THE RACK AND PINION. I AM ISSUING THIS COMPLAINT BECAUSE I WAS TOLD BY THE DEALER THAT CHEVORLET HAS NO REPAIR TO ELIMINATE THE NOISE. I CONSIDER ANY PART OF MY STEERING A VERY SAFETY SENSITIVE ISSUE. IF IT WERE ONLY ONE CAR I WOULD NOT BE AS CONCERNED. BUT I BELIEVE IT SHOULD BE CORRECTED (ON GM'S NICKEL OF COURSE) ASAP!*JB

BOTH YELLOW DAYTIME RUNNING LIGHT COVERS ARE MELTED. THERE IS A BURN MARK SURROUNDING THE HOLES OVER EACH LIGHT BULB -- ON BOTH THE RIGHT AND THE LEFT SIDE OF THE VEHICLE. THE CLEAR PLASTIC SHELL AROUND THE HEADLIGHT IS DISCOLORED AS A RESULT OF THE EXCESS HEAT. *JB

2004 CHEVROLET MALIBU WITH NOISE IN THE STEERING WHEEL CUSTOMER STATES THAT THIS PROBLEM HAS BEEN GOING FOR 2 YEARS WITHOUT CORRECTION FROM THE DEALERSHIP**CC THE DEALER REPLACED VARIOUS PARTS IN THE STEERING, HOWEVER THE PROBLEM REMAINED THE SAME. THE BATTERY WAS REPLACED. THE VEHICLE HESITATED TO START. THE DEALER FOUND THE IGNITION SWITCH HAD SHORTED OUT INTERNALLY. THE HORN WAS REPLACED. THE CD PLAYER MADE A CLICKING SOUND. *JB

TL*THE CONTACT OWNS A 2004 CHEVROLET MALIBU. WHILE DRIVING AT VARIOUS SPEEDS, THE STEERING LOCKED UP AND WAS UNABLE TO MANEUVER PROPERLY. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC AND THEY FOUND NOTHING WRONG. SHE TOOK THE VEHICLE TO ANOTHER MECHANIC WHO CLAIMED TO KNOW THE CAUSE OF FAILURE, BUT DID NOT HAVE TIME TO MAKE THE REPAIR. THE POWERTRAIN WAS UNKNOWN. THE CURRENT MILEAGE WAS 50,000 AND FAILURE MILEAGE WAS 48,000.

MY WIFE AND BOUGHT A 2004 CHEVY MALIBU IN JULY 2004. IN MARCH 2007 MY TURN SIGNALS BEGAN TO FAIL, BOTH THE LEFT AND RIGHT SIDES. ALSO, THE RIGHT SIDE AMBER COVER ON THE RUNNING LIGHTS HAS A HOLE BURNT IN THE TOP OF IT AND THE LEFT SIDE IS BEGINNING TO BURN THRU NOW. I REPLACED SEVERAL BULBS AND ALSO TOOK IT THE DEALERSHIP THAT WE PURCHASED IT FROM; THE FIRST TIME THEY REPLACED THE BULBS AND THE TURN SIGNALS WORKED FOR ABOUT 1 HOUR AFTER LEAVING THE DEALERSHIP. I TOOK THE VEHICLE BACK AND WAS TOLD THAT I NEEDED TO HAVE THE SOCKETS REPLACED, THE SOCKETS WERE REPLACED AND EVERYTHING WORKED FINE FOR 2 MONTHS AND THE PROBLEM HAPPENED AGAIN, SO BACK TO THE DEALERSHIP I WENT AND THIS TIME I WAS TOLD THAT I NEEDED TO HAVE BOTH COMPLETE HEADLAMP ASSEMBLIES REPLACED. THERE'S OBVIOUSLY A MAJOR PROBLEM WITH THESE VEHICLES. SOONER OR LATER THIS SITUATION WILL RESULT IN A FIRE AND POSSIBLY BODILY INJURIES AND PROPERTY DAMAGE. WHAT IS GOING TO TAKE BEFORE GM WAKE UP? THERE ARE NO RECALLS FOR THIS ISSUE.... *TR

PROBLEMS WITH THE:"RACK AND PINION STEERING , BRAKES, FRONT SUSPENSION. *AK

IN SEPTEMBER 2005 I TOOK THE 2004 CHEVROLET MALIBU TO THE DEALER TO CHECK A PROBLEM IN THE STEERING COLUMN . THE DEALERSHIP FIXED THE PROBLEM AND THE MANAGER AS MUCH AS ADMITTED THAT THERE WAS SOMETHING DEFECTIVE IN THE STEERING COLUMN OF THAT PARTICULAR VEHICLE. I PAID FOR THE REPAIRS, BUT I IMMEDIATELY CALLED GENERAL MOTORS, AND TOLD SOME ONE THERE THAT I DIDN'T THINK IT WAS RIGHT TO BE CHARGED FOR A REPAIR ON SOMETHING IN THE VEHICLE THAT WAS KNOWN TO BE DEFECTIVE. THAT OFFICE THEN CALLED THE DEALERSHIP AND SPOKE TO THE MANAGER AND THEY REIMBURSED ME FOR THE REPAIR. WELL, NOW THE STEERING WAS ACTING UP AGAIN. THIS TIME THE VEHICLE PULLED STRONGLY TO THE LEFT WHEN BEING DRIVEN. IT ALSO MADE A STRANGE NOISE WHEN TURNING THE WHEEL, SIMILAR TO THE ONE IT MADE PREVIOUSLY WHEN REPAIRS HAD TO BE DONE. I HAD THE VEHICLE CHECKED SEVERAL TIMES ,AND HAVE BEEN TOLD THAT THEY COULD NOT FIND ANYTHING WRONG. TOMORROW I AM GOING TO ASK THEM TO CHECK INTO THE ACTUAL STEERING MECHANISM TO SEE IF THAT WAS WHERE THE PROBLEM WAS COMING FROM. IF I AM RIGHT I WOULD LIKE TO KNOW IF I WILL BE ABLE TO GET THE MANUFACTURER OF THIS VEHICLE TO APPROVE OF PAYING FOR THE REPAIR.*AK

TL*THE CONTACT OWNS A 2004 CHEVROLET MALIBU. WHILE MAKING A LEFT TURN AT 10 MPH, THE POWER STEERING FAILED. THE FAILURE OCCURRED THREE TIMES. THE ENGINE SIZE AND PURCHASE DATE WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 40,500.

CAR WAS MAKING CLUNKING NOISE IN THE STEERING WHEEL/TIRE AREA WHEN MAKING TURNS. DEALER REPLACED INTERMEDIATE STEERING SHAFT. THIS WAS THE THIRD TIME INVOLVING A STEERING ISSUE. REPLACED STEERING GEAR ASSEMBLY AND RACK & PINION. *AK

I HAVE HAD THE SAME ISSUE WITH MY CAR A CLUNKING SOUND IN THE TIRE AREA WHEN MAKING TURNS. THIS IS THE 4TH TIME I HAVE HAD MY CAR IN FOR SERVICE ON THIS SAME ISSUE.

THE LEFT FRONT TURN SIGNAL HAD TO BE REPLACED AROUND 9 TIMES IN THE THREE YEARS I HAVE OWNED THE CAR. *AK

THERE WA SA CLUNCKING SOUND EVERY TIME I TURNED THE WHEEL TO THE LEFT OR THE RIGHT. I SENT THE CAR TO THE DEALER ON TWO OCCASIONS FOR REPAIRS, AND THEY REPLACED THE STEERING COLUMN BOTH TIMES, THE CAR STILL CLUNCKED. .THE DEALER SAID THE CLUNCKING SOUND WAS OKAY AND NOT TO BRING IT BACK.THE RIGHT WHEEL BEARING WAS REPLACED, AND NOW THE GAS GAUG EFAILED. 1 WAS TOLD WHEN THE GAS GAUGE FAILURE WAS AN EARLY WARNING THAT THE FUEL PUMP WILL SOON NEED TO BE REPLACED.*AK

THERE WAS A CLUNCKING SOUND EVERY TIME I TURN THE WHEEL TO THE LEFT OR THE RIGHT. I TOOK THE CAR TO THE DEALER ON TWO OCCASIONS FOR REPAIR, AND THEY REPLACED THE STEERING COLUMN BOTH TIMES, THE CAR STILL CLUNCKED. .THE DEALER SAID THE CLUNCKING SOUND WAS OKAY AND NOT TO BRING IT BACK.THE RIGHT WHEEL BEARING WAS REPLACED, AND NOW THE GAS GAUGE DID NOT WORK. ALSO, I WAS TOLD WHEN THE GAS GAUGE FAILED IT WA S AN EARLY WARNING THAT THE FUEL PUMP WILL SOON NEED TO BE REPLACED. *AK

THE HORN ON MY VEHICLE FAILED. THIS LED TO A NEAR COLLISION AS I WAS UNABLE TO UTILIZE THE HORN TO ALERT THE OTHER DRIVER TO MY PRESENCE. I TOOK MY 2004 MALIBU TO MY MECHANIC WHO REPLACED THE FUSE. THE HORN WORKED FOR ABOUT A DAY AND THEN WHEN BEING OPERATED BY ANOTHER DRIVER, HE TRIED TO USE THE HORN WHEN ANOTHER VEHICLE RAN A RED LIGHT AND THE HORN DID NOT WORK. PER THE MECHANIC THE FUSE BLEW AGAIN. HE RAN A CHECK ON SERVICE NOTICES FOR THE VEHICLE AND FOUND THAT CONDENSATION FORMS IN THE LOCATION OF THE HORN DUE TO A KNOWN DEFECT IN THE LOCATION. GM IS AWARE OF THIS, BUT HAS NOT ISSUED A RECALL EVEN THOUGH THE MECHANIC STATES THAT IT CAUSES THE HORN TO QUIT SUDDENLY AND THE AVERAGE CONSUMER WILL BELIEVE IT IS THE FUSE, REPAIR THAT ONLY TO HAVE THE HORN FAIL AGAIN WITHIN DAYS. *TR

TL*THE CONTACT OWNS A 2004 CHEVROLET MALIBU. THE CONTACT STATED THAT THE VEHICLE'S EXTERIOR FRONT TURN SIGNAL CONSISTENTLY FAILS. THE VEHICLE PURCHASE DATE WAS UNKNOWN. THE CURRENT MILEAGE IS 46,793 AND FAILURE MILEAGE WAS 44,532.

TL-CALLER IS LEASING A 2004 CHEVROLET MAILBU. CURRENT AND FAILURE MILEAGE 48000. WHILE DRIVING AT 3MH AND ATTEMPTING TO ENTER TRAFFIC,THE CAR DIED WITH NO WARNING. STEERING FROZE. SHE WAS ABLE TO RESTART THE VEHICLE AND TOOK IT TO DEALER LATER THAT DAY. THE STEERING WAS REPLACED HOWEVER THE ENGINE PROBLEM WAS A MYSTERY TO THEM. WEATHER WAS DRY TEMPERATURE UNKNOWN. THE VEHICLE HAS BOTH MANUAL AND AUTOMATIC. KTF

AUTO: 2004 CHEVROLET MALIBU LS - FRONT TURN SIGNAL-DAYTIME RUNNING LIGHT MELTED A HOLE IN THE AMBER LENS ON BOTH SIDES OF THE CAR. GRAND PRIZE CHEVROLET OF MIAMI REPLACED BOTH HEADLIGHT ASSEMBLY'S . HAVE SEEN OTHER MALIBUS WITH THE SAME PROBLEM AND I AM TRYING TO FIND OUT IF THIS IS GOING TO BE A RECURRING PROBLEM. I HAVE NOTICED THAT ON NEWER MODELS THE DAYTIME RUNNING LIGHTS ARE NOW THE HEADLIGHTS INSTEAD OF THE TURN SIGNAL LAMPS. *TR

POWER STEERING WAS DISPLAYED ON MESSAGE CENTER AND A LIGHT WITH VEHICLE AND WRENCH CAME ON FOR A SHORT PERIOD. DIAGNOSTICS WERE PERFORMED AND FOUND CODE CC0460. THIS WAS TRACED TO A SHORTED STEERING SENSOR. THEY HAD TO REPLACE THE WHOLE STEERING COLUMN BECAUSE THE SENSOR IS PART OF THE ASSEMBLY. I HAVE READ NUMEROUS COMPLAINTS ABOUT THE POWER STEERING LIGHT BEING DISPLAYED ON THE MESSAGE CENTER AND THEN THE POWER STEERING WENT OUT ON THE CAR. MY POWER STEERING DID NOT GO OUT ON THE CAR BECAUSE I DROVE IT TO THE DEALERSHIP RIGHT AWAY. I WAS WONDERING IF THERE IS A RECALL OR SERVICE BULLETINS ON THIS PROBLEM TO OFF SET THE COST OF REPAIRS FOR THE SENSOR, WHICH HAS TO BE REPLACED WITH A WHOLE STEERING COLUMN, FOR A TOTAL OF $850.12 IN PARTS AND LABOR. THANK YOU. *JB

2004 MALIBU CUSTOMER HAS HAD PROBLEMS WITH LOSS OF ELECTRIC POWER STEERING AND WANTS OUT OF THE LEASE WITHOUT PENALTY**CC THE RADIO WAS INOPERATIVE, THE CRUISE CONTROL WAS INOPERATIVE AT TIMES, IT WOULD TURN OFF, BUT NOT ENGAGE. THE PCM WAS REPLACED. THE PASSENGER SIDE DIRECTIONAL LIGHTS AND BRAKE LIGHTS WERE INOPERATIVE. THE DEALER REPLACED THE BULBS. THE HEATED SEATS CAME ON BY THEMSELVES. THE INTERMEDIATE SHAFT WAS REPLACED, BECAUSE THE CONSUMER STATED THERE WAS A NOISE WHEN TURNING THE STEERING WHEEL. THE TRANSMISSION COOLING LINES WERE LEAKING, THE REAR DEFOGGER ON THE PASSENGER SIDE WAS INOPERATIVE. WHEN THE WINDSHIELD WIPERS WERE ON INTERMITTENT, THEY WOULD GO FULL SPEED BY THEMSELVES. *JB

TL* - THE CONTACT OWNS A 2004 CHEVROLET MALIBU. THE CONTACT STATED THAT WHILE DRIVING ON 09/23/06 THE STEERING BECAME VERY HARD. THE CONTACT WAS JUST ABLE TO STEER THE VEHICLE AND PARK IT. THE VEHICLE WAS TOWED, AND IT WAS FOUND THAT THE STEERING MODULE DID NOT WORK. THE STEERING MODULE WAS REPLACED ON 09/27/06. HOWEVER, BECAUSE THE VEHICLE OWNER BELIEVED THIS WAS A HAZARD HE WAS AFRAID TO DRIVE THE VEHICLE. THE CURRENT AND FAILURE MILEAGE WERE BOTH 10905 MILES.*AK UPDATE 4/9 *TR

TL* - THE CONTACT HAS A 2004 CHEVROLET MALIBU LS. THE CONTACT STATED THAT WHEN SHE TURNED THE IGNITION ON THE ENHANCED TRACTION SYSTEM WARNING LIGHT, THE ENGINE LIGHT, AND THE SERVICE LIGHT CAME ON. THE CAR WOULD START AND ALL OF THE DASHBOARD FEATURES WOULD WORK, BUT THE CAR WOULD NOT SHIFT INTO THE REVERSE OR DRIVE GEARS. THE CONTACT STATED SHE COULD PUT THE CAR IN THE DRIVE GEAR AND IT WOULD NOT DRIVE. THE CAR BEGAN TO JERK AND SHAKE WITHOUT THE CONTACT ADDING PRESSURE TO THE ACCELERATOR PEDAL, AND THE RPM LEVEL INCREASED. THE CONTACT STATED THAT THE VEHICLE HAS NEVER DONE THIS BEFORE. THE WEATHER WAS REALLY COLD AND THERE WERE SNOW FLURRIES, BUT NO ACCUMULATION.

TL * - THE CONTACT STATED THAT HE RECEIVED RECALL LETTER 04050. THE CONTACT HAD A COMPUTER CHIP IN THE POWER STEERING MODULE REPLACED IN JAN 2005 BECAUSE OF THE RECALL. THE CONTACT STATED THE POWER STEERING FAILURE RETURNED THREE MONTHS LATER. THE CONTACT TOOK THE VEHICLE BACK TO THE DEALER ,AND THE VEHICLE WAS DIAGNOSED WITH NEEDING ANOTHER COMPUTER CHIP FOR THE POWER STEERING. THE DEALER WOULD NOT REPLACE THE CHIP FOR FREE BECAUSE IT HAD ALREADY BEEN REPLACED UNDER THE RECALL. THE POWER STEERING FAILED INTERMITTENTLY FOR THE PAST TWO YEARS. THE POWER STEERING WARNING LIGHT CAME ON WHEN THE POWER STEERING WAS NOT WORKING. *AK UPDATED 1/31/2007 - *NM

DT*: THE CONTACT STATED THE VEHICLE LOST POWER STEERING CONTROL NEARLY CAUSING AN ACCIDENT. THE VEHICLE WAS TAKEN TO A SERVICE DEALER COULD NOT DUPLICATE THE ISSUE.

COOLANT LOW INDICATOR CAME ON DASH BOARD. TOOK CAR TO DEALERSHIP WAS ADVISED COOLANT LEAKING ON GASKET. PARTS WERE REPLACED, ENGINE LIGHT THEN CAME ON NEXT DAY TOOK CAR BACK WAS ADVISED NEEDED TO ORDER PART FOR CATALYTIC CONVERTER. PARTS STILL HAVEN'T CAME IN AND ENGINE LIGHT STILL ON. WAS TOLD THE MALIBU HAS A COMPLEX EXHAUST SYSTEM. *NM

AFTER ONE YEAR OF DRIVING OUR 2004 MALIBU (ABOUT 20, 000 MILES), THE SIGNAL LIGHTS BEGAN FAILING. REPLACEMENT OF THE BULBS BY A GM DEALER SOLVED EACH PROBLEM (4 INCIDENTS). THEN ABOUT TWO WEEKS AGO THE RIGHT FRONT SIGNAL REVEALED AN ELECTRICAL SHORT IN THE WIRING HARNESS, WHICH WAS REPLACED AT OUR EXPENSE. TODAY THE LEFT REAR SIGNAL SOCKET AND HARNESS HAVE THE SAME PROBLEM. THERE APPEARS TO BE A MANUFACTURING OR DESIGN DEFECT IN THE SIGNAL LIGHT SYSTEM. *NM

DT*: THE CONTACT STATED THE VEHICLE'S POWER STEERING LOCKED UP. THE SERVICE DEALER DETERMINED THE VEHICLE NEEDED A NEW STEERING COLUMN TO RESOLVE THE ISSUE. UPDATED 12/15/2006 - *NM

LOSS OF POWER STEERING IN MY 2004 MALIBU. HAD STEERING SYSTEM REPLACED BY RECALL 05, SINCE THEN, THE STEERING STARTING MAKING NOISE, HAD TO HAVE STEERING RODS ADJUSTED, NOW I HAD TO REPLACE THE STEERING GEAR AT COST OF $495.00. IT STILL MAKES SOME NOISE WHEN TURNING TO RIGHT, NEED GM TO COMPENSATE FOR THESE EXPENSES, HAD NOTHING BUT STEERING PROBLEMS FROM ON SET. HELP. *NM

THE STEERING COLUMN WAS REPLACED IN APRIL OF 2005 AS A RESULT OF A RECALL STATING THAT THE POWER STEERING ASSIST CAN FAIL WITHOUT WARNING. UP TO THIS TIME, NO ACTUAL FAILURE HAD OCCURRED. IN SEPTEMBER OF 2006 THE POWER STEERING ASSIST FAILED FOR THE FIRST TIME AS DESCRIBED IN THE RECALL NOTICE. SIMULTANEOUS WITH THE FAILURE, AN AUDIBLE BEEPING OCCURRED AND A FAILURE MESSAGE WAS DISPLAYED ON THE CONSOLE. RE-STARTING THE CAR WILL CORRECT THE PROBLEM TEMPORARILY, BUT IT RECURS ON A REGULAR BASIS. BOTH THE DEALER AND MANUFACTURER REFUSE TO REPLACE THE STEERING COLUMN AT THEIR EXPENSE BECAUSE IT WAS DONE ONCE IN 2005. *NM

THREE ISSUES WITH MY 2004 CHEVROLET MALIBU LS V6... 1. THE STEERING GEAR NEEDS TO BE REPLACED AT 48,000 MILES. 2. THE STARTER STAYS ENGAGED PERIODICALLY OR HAS TROUBLE TURNING OVER TO START THE CAR. 3. A/C NOT COOLING VEHICLE. ENTIRE UNIT EVENTUALLY REPLACED. THE VEHICLE HAS BEEN BROUGHT IN NUMEROUS (13) TIMES TO VARIOUS GM DEALERS AND ONLY HAS 48,000 MILES. *JB

DT*: THE CONTACT STATED THE STEERING LOCKED UP ON 2 SEPARATE OCCASIONS. THE CONTACT BELIEVES THE ELECTRIC STEERING HAS LOST POWER AND THE WHEELS BECOME LOCKED. BOTH TIMES THE DEALER HAS REPLACED THE RACK PINION ROD, BUT THE CONTACT EXPRESS THAT THIS WILL HAPPEN AGAIN AND WAS PROBABLY DUE TO A COMPONENT DEFECT.

POWER STEERING FAILED ON 2004 CHEVY MALIBU WITHOUT WARNING. I HAD TAKEN THE CAR IN ABOUT A MONTH AGO FOR FRONT ALIGNMENT ISSUES, THOUGHT THEY FIXED IT, BUT THE PROBLEM CAME BACK AND THEN POWER STEERING QUIT. *JB

DT*: THE CONTACT STATED WHILE DRIVING ON THE FREEWAY, THE STEERING COLUMN LOCKED UP. THE 2004 CHEVROLET WAS THE FIRST YEAR MANUFACTURED WITH A ELECTRIC STEERING COLUMN. IN APRIL 2005, THE STEERING COLUMN WAS MAKING A NOISE AND WAS TIGHT RESULTING IN DIFFICULT STEERING FOR SHARP TURNS. TO CORRECT THE PROBLEM, THE DEALER REPLACED THE STEERING COLUMN. IN JULY 2006, THERE WAS A SECOND FAILURE TO THE STEERING COLUMN, IT LOCKED UP.

IN TWO OCCASIONS I EXPERIENCED A COMPLETE LOSS OF STEERING .THE CAR A CHEVROLET MODEL MALIBU YEAR 2004 WAS TRANSPORTED TO A CHEVROLET DEALER(NORWOOD CHEVROLET) IN WARWICK RI. THE MECHANIC DIAGNOSED A STEERING COLUMN SHIFT-TORQUE SENSOR FAILURE.GM ADMITTED THAT THEY HAD AN INTERNAL RECALL. THE STEERING COLUMN WAS REPLACED AS PER GM CUSTOMER RELATION MANAGER.THE BILL WAS 610.48 DOLLARS.THEYNEVER REFUND ME BECAUSE THE NEW MANAGER STATED THAT THE RECALL WAS LIFTED.PLEASE EVALUATE AND ADVISE ME WHAT TO DO. THANK YOU . *NM

DRIVING DOWN THE ROADWAY AND MY CHILD WHO IS 4 IN THE BACKSEAT OPENED THE PASSENGER SIDE DOOR. THERE IS NO REAR CHILD SAFETY LOCK ON THE 2004 AND 2005 CHEVY MALIBU'S. YET 02 HAD THEM. *NM

DT*: THE CONTACT STATED WHILE DRIVING THERE WAS A DETECTION OF GASOLINE ODOR COMING FROM THE REAR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT REPAIR SHOP. DURING THE INSPECTION, THE GAS TANK WAS REMOVED AND THE GAS LINE ON THE TOP SIDE OF THE TANK WAS OBSERVED TO BE RUPTURED WHICH CAUSED GASOLINE TO SPEW UNDER VEHICLE. THE MANUFACTURER HAS BEEN ALERTED.

2004 MALIBU ANTI THEFT LIGHT AND RADIO LOCK LIGHT ILLUMINATES, PROBLEM WITH SEAL ON THE REAR LEFT WINDOW. *TS THE STEERING WAS STIFF, THE MOLDING ON THE LET REAR WINDOW CAME OUT OF PLACE WHEN THE WINDOW WAS ROLLED UP. THE VEHICLE WOULD VIBRATE WHILE DRIVING. THERE WAS A RUBBING NOISE COMING FROM THE FRONT OF THE VEHICLE, THE CHECK ENGINE LIGHT ILLUMINATED SEVERAL TIMES, THE TEMPERATURE AND FUEL GAUGE LIGHT ILLUMINATED. THE TRUNK WOULD NOT OPEN PROPERLY WHEN USING THE REMOTE. THE VEHICLE STARTED BY ITSELF AND ALL THE LIGHTS ILLUMINATED WHICH CAUSED THE BATTERY TO DIE. *JB

DT*: THE CONTACT STATED THAT THE FRONT AXLE SEALS WERE LEAKING. THE ISSUE HAS GRADUALLY WORSENED. NEW AXLE SEALS WERE INSTALLED ON THE VEHICLE BUT THE PROBLEM IS STILL PERSISTS. . *AK

DURING MY EMPLOYMENT CONTRACT WITH DELPHI AUTOMOTIVE (DELPHI SAGINAW STEERING SYSTEM, 3900 E. HOLLAND AVE., SAGINAW, MICHIGAN 48601), I WAS INSTRUCTED TO CONDUCT A SCREW "STRIP-OUT" STUDY ON THE ELECTRIC MOTOR/CONTROLLER ASSEMBLY OF THE ELECTRIC POWER STEERING (EPS) SYSTEM OF THE GENERAL MOTOR'S EPSILON PLATFORM (MY 2003.5 - 2006 MALIBU). THIS STUDY WAS CONDUCTED IN MAY OF 2004 AT DELPHI'S PLANT 1, EPS ASSEMBLY. THE STUDY INCLUDED TEN PRODUCTION MOTOR AND TEN PRODUCTION CONTROLLER ASSEMBLIES THAT WERE ASSEMBLED ON THE PRODUCTION EQUIPMENT AND PROCESS(ES). THE CONTROLLER IS ATTACHED TO MOTOR BY THREE M 5.0X 0.8 SCREWS. THE RESULT OF THAT STUDY CONCLUDED THAT FOUR OF THE TEN MOTOR/CONTROLLER ASSEMBLIES HAD AT LEAST ONE OF THE SCREWS FULLY STRIPPED WITH LESS THAN 50% OF THE DESIGN INTENDED RETENTION AND WITH TWO ASSEMBLIES WITH TWO FULLY STRIPPED SCREWS. THIS REPORT WAS SHARED WITH MY IMMEDIATE ENGINEERING MANAGER WHOM THEN REPORTED TO SEVERAL OTHER PRODUCT ENGINEER MANAGERS OF THE EPS GROUP IN SAGINAW, MICHIGAN. IT WAS UNIVERSALLY UNDERSTOOD THAT PLANT 1 HAD AN ASSEMBLY ISSUE WITH THIS PROCESS AND THAT THERE WAS NO EFFECTIVE CONTAINMENT PROCESS IN PLACE TO SCRAP ALL SUSPECTED STRIPPED ASSEMBLIES. THE FOLLOW-UP INFORMATION FROM MY MANAGERS THAT I UNDERSTOOD WAS THAT UAW ASSEMBLY MEMBERS WERE INQUIRED TO AGREE AMONG THEMSELVES A BUILD SEQUENCE FOR THE CONTROLLER FASTENING PROCESS SO THAT THE COMPONENTS COULD BE REDESIGNED FOR BETTER ASSEMBLY. THIS ITEM WAS NOT PURSUED BECAUSE IT

I PURCHASED MY 2004 MALIBU ON THE DATE LISTED AS INCIDENT DATE. AFTER BRINGING HOME AND DRIVING A BIT, I BEGAN TO NOTICE A CLUNKING NOISE UNDER THE FRONT FLOOR WHEN GOING OVER BUMPS AND TURNING THE STEERING WHEEL. THIS IS ESPECIALLY NOTICEABLE AT LOW SPEEDS. *JB

DT*: THE CONTACT STATED WHILE ATTEMPTING TO MAKE EITHER A LEFT OR RIGHT TURN THERE IS A KNOCKING NOISE PRESENT IN THE STEERING OF THE VEHICLE. WHILE DRIVING AT ANY SPEED THE VEHICLE PULLS TO LEFT. THE VEHICLE WAS TAKEN TO THE DEALER ON 3 OCCASIONS AND THE MANUFACTURER HAS BEEN ALERTED HOWEVER THERE IS NO FIX FOR THESE PROBLEMS.

VEHICLE LOSES POWER STEERING CAUSING LOSE OF CONTROL WHILE DRIVING. THIS FIRST OCCURRED 12/7/04 AND WAS REPAIRED UNDER GM CUSTOMER SATISFACTION CAMPAIGN 04050A (RECALL). VEHICLE LOST STEERING CONTROL AGAIN WHILE DRIVING ON 2/20/06, VEHICLE WAS REPAIRED. VEHICLE LOST STEERING CONTROL, ENGINE STALLED AND BRAKES FAILED WHILE DRIVING 55 MPH ON INTERSTATE FREEWAY ON 2/27/06, VEHICLE WAS REPAIRED. VEHICLE LOST STEERING CONTROL AGAIN ON 5/11/06. VEHICLE IS UNSAFE TO DRIVE AND HAS NOT BEEN REPAIRED TO MAKE SAFE. *NM

DT*: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS THE STEERING LIGHT ILLUMINATED. AFTER INSPECTION THE DEALERSHIP REPLACED THE COMPUTER CHIP IN THE ELECTRONIC STEERING SYSTEM. AFTERWARDS THERE WAS A KNOCKING SOUND WHILE TURNING. ALTHOUGH THE DEALER REPLACED THE STEERING SHAFT THE KNOCKING CONTINUED. THE VEHICLE WAS RETURNED TO THE DEALER WHERE THE STEERING RACK AND PINION IS BEING REPLACED.

I BOUGHT A 2004 CHEVY MALIBU IN AUGUST OF 2004. SINCE THAT TIME ALL 4 SIGNAL LIGHTS AND ONE HEADLIGHT ASSEMBLY HAVE BURNT OUT AND NEEDED TO BE REPLACED. THE LEFT REAR SIGNAL LIGHT IS NOW INOPERABLE. MAKING THIS THE 5 TIME I HAVE HAD PROBLEMS WITH THE SIGNAL LIGHTS. I HAVE ASKED THEM (CHEVROLET SERVICE DEPARTMENT) TO CHECK THE ENTIRE ELECTRICAL SYSTEM EVERY TIME AND EVERY TIME THEY TELL ME THAT THE PROBLEM HAS BEEN RESOLVED. SEVERAL TIMES THE WORK INVOICE COPY SAID, "REPLACED SIGNAL LIGHT BULB" THERE APPEARS TO BE A MORE SERIOUS ISSUE TO THIS PROBLEM AND I SEE THAT I AM NOT THE ONLY ONE THAT IT HAS HAPPENED TO. ALTHOUGH NO FIRE HAS OCCURRED, I FEEL THAT THERE IS DEFINITE SAFETY HAZARD WHEN IT UNEXPECTEDLY STOPS OPERATING BECAUSE YOU ARE UNABLE TO SIGNAL OTHER DRIVERS THAT YOU ARE TURNING. *JB

DT*: THE CONTACT STATED THE DEFOGGER SYSTEM PULLS AIR FROM OUTSIDE OF THE VEHICLE. WHILE DRIVING IN CONGESTED TRAFFIC, THE POLLUTED AIR FROM THE OTHER VEHICLES IS PULLED INSIDE THE CONTACT'S VEHICLE. THE DEALERSHIP HAS BEEN INFORMED.

DT*: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS THE VEHICLE WAS DIFFICULT TO STEER AND THE BRAKES VIBRATED. THE DEALERSHIP DETERMINED THE TIE ROD HAD BROKEN AND REPAIRED THE VEHICLE.

DT*: THE CONTACT STATED THE RIGHT FRONT TURN SIGNAL STOPPED WORKING WITHOUT WARNING. UPON INITIAL INSPECTION, THE AMBER LENS INSIDE THE HEADLIGHT HOUSING HAD VISIBLE DAMAGE ON THE HEADLIGHT ASSEMBLY AS THOUGH IT HAD BURNED. THERE WERE NO VISIBLE FLAMES OR SMOKE TO INDICATE A FIRE. THE DEALER WAS ALERTED, BUT NO REPAIRS WERE MADE.