IllustrationCONSUMER RECEIVED A RECALL NOTICE(04002) REGARDING THE IGNITION CIRCUIT THERMAL. THE DEALER REFUSED TO DO THE WORK!!! SERVICE MANAGER PATRICIA BARONA. *JB THE CONSUMER REQUESTED THAT THE INFORMATION GIVEN TO BE DISREGUARDED BECAUSE INFORMATION WAS ON THE CONSUMERS 2001 THAT WAS TRADED FOR 2004. *TC
2004 Chevrolet Cavalier
Owner reports · Recalls · Investigations
More warning signs than most Cavalier years
Owner complaints for the 2004 Chevrolet Cavalier are substantially higher than the model-year median of 140.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cavalier years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
430–25K
7225–50K
6150–75K
3475–100K
36100–150K
18150K+
264 reports with mileage · 66 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 185 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Vehicle Speed Control. Review the 27 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
17 crash reports6 fire reports15 injury reports
Electrical System complaints
185 reportsWHEN STARTING THE VEHICLE, EVERY MONTH OR SO IT WILL TURN OVER ONCE AND THE POWER WILL SHUT OFF AND WHEN I LET OFF THE KEY IT WILL COME BACK ON. THEN TRY TO START AGAIN AND IT WILL. MAYBE A PROBLEM WITH THE IGNITION OR STARTER.*AK
CONSUMER COMPLAINED THAT WHEN MANUALLY SHIFTING VEHICLE STALLED. THE KEY HAD TO BE REMOVED FROM THE IGNITION TO RESTART THE VEHICLE. ALSO, SOMETIMES VEHICLE STALLED WHEN SHIFTING TOO FAST. OCCASIONALLY, THE STALLING OCCURRED ON THE HIGHWAY. DURING THIS TIME IT COULD BE DANGEROUS TO HAVE TO REMOVE THE KEY FROM THE IGNITION. …
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CONSUMER COMPLAINED THAT WHEN MANUALLY SHIFTING VEHICLE STALLED. THE KEY HAD TO BE REMOVED FROM THE IGNITION TO RESTART THE VEHICLE. ALSO, SOMETIMES VEHICLE STALLED WHEN SHIFTING TOO FAST. OCCASIONALLY, THE STALLING OCCURRED ON THE HIGHWAY. DURING THIS TIME IT COULD BE DANGEROUS TO HAVE TO REMOVE THE KEY FROM THE IGNITION. THE DEALER CLAIMS THAT THE VEHICLE WAS DESIGNED TO DO THIS. THE PROBLEM OCCURRED MORE THAN TWELVE TIMES. *AK *NM
A STRONG FUEL ODOR ENTERED THE INSIDE OF THE VEHICLE WHEN THE VENTS WERE USED. THIS ODOR CAUSED NAUSEA AND HEADACHES TO ANY ONE RIDING IN THE VEHICLE. AT ANY TEMPERATURE, THE VEHICLE TOOK A VERY LONG TIME TO CRANK UP. ALSO, WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY DECELERATED AND BOGGED DOWN. THE VEHICLE WOULD EVEN…
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A STRONG FUEL ODOR ENTERED THE INSIDE OF THE VEHICLE WHEN THE VENTS WERE USED. THIS ODOR CAUSED NAUSEA AND HEADACHES TO ANY ONE RIDING IN THE VEHICLE. AT ANY TEMPERATURE, THE VEHICLE TOOK A VERY LONG TIME TO CRANK UP. ALSO, WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY DECELERATED AND BOGGED DOWN. THE VEHICLE WOULD EVENTUALLY PICK UP SPEED AND ACT AS IF NOTHING EVER HAPPENED. THESE PROBLEMS OCCURRED EIGHT TIMES. *AK THERE WAS RATTLE IN THE DRIVERS SIDE DOOR PANEL DUE TO THE REGULATOR, THERE WAS ALSO AN INTERMITTENT NOISE ON THE PASSENGER SIDE REAR, THE VEHICLE WOULD NOT START DUE TO THE POWER TRAIN CONTROL MODULE, THE ENGINE WAS HARD TO START AT TIMES AND WAS UNABLE TO BE DUPLICATED, THE ENGINE WOULD LOSE POWER, THE DRIVER DOOR MADE A RUBBING NOISE, THE FLOOR AREA WAS BUCKLING, AND THE A/C DISPLAYED A BURNING SMELL. *SC *JB
CONSUMER STARTED VEHICLE TO WARM IT UP AND WENT BACK INTO THE OFFICE. VEHICLE WAS IN FLAMES WITHIN 10 MINUTES. THE FLAMES WERE UNDER THE HOOD. *AK
Official recalls
104V300000 · Seat Belts:rear/other
Jun 23, 2004
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.
Consequence & remedy
Consequence: 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.
Remedy: 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.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
0No exact-year investigations in this snapshot.