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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 →

When problems were reported

Mileage at the reported incident

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

Power Train complaints

23 reports
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85,509 miles · Dec 13, 2020
Power Train

IN THE PARKING LOT WHERE I WORK MY CAR WOULD NOT START. WHEN MOVING THE AUTOMATIC TRANSMISSION LEVER IT DID NOT CATCH ON TO ANYTHING. THE CAR JUST ROLLED BACKWARDS AND I HAD TO IMMEDIATELY PRESS ON THE BRAKES PREVENTING AN ACCIDENT. MY CAR HAD TO BE TOWED TO THE AUTO SHOP. DIAGNOSIS: SHIFTER CABLE WAS DETACHED FROM TRANSMISSION.…

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IN THE PARKING LOT WHERE I WORK MY CAR WOULD NOT START. WHEN MOVING THE AUTOMATIC TRANSMISSION LEVER IT DID NOT CATCH ON TO ANYTHING. THE CAR JUST ROLLED BACKWARDS AND I HAD TO IMMEDIATELY PRESS ON THE BRAKES PREVENTING AN ACCIDENT. MY CAR HAD TO BE TOWED TO THE AUTO SHOP. DIAGNOSIS: SHIFTER CABLE WAS DETACHED FROM TRANSMISSION. PREVIOUSLY ON 09/13/2011 THE SAME THING HAPPENED TO MY CAR. THE SHIFTER CABLE BROKE AND I HAD TO BE TOWED TO LOU BACHRODT CHEVROLET BOTH TIMES. THE 2ND TIME INVOICE NO. CWCS692729 $502.24 AND $477.55 INVOICE NO.CWCS149491 THE FIRST TIME. THIS CAR SHOULD BE RECALLED. TWO TIMES IS TOO MANY.

NHTSA ODI #11383222

109,000 miles · Apr 3, 2015
Power Train

BOUGHT USED HAD 109000 FIRST TIME THE CLUTCH WENT OUT ON ME I WAS EXHILARATING TO MOVE INTO HEAVY FREEWAY TRAFFIC AND IT GOES OUT, ESPECIALLY AS A YOUNG WOMAN I WAS VERY SCARRED FOR MY LIFE TO THIS DAY I HAVE NIGHTMARES, GOT IT FIXED BUT NO REALLY CAUSE IT STILL DOES IT WE JUST HAVE TO KEEP PUTTING DOT 3 AT THE CLUTCH LINE. ITS…

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BOUGHT USED HAD 109000 FIRST TIME THE CLUTCH WENT OUT ON ME I WAS EXHILARATING TO MOVE INTO HEAVY FREEWAY TRAFFIC AND IT GOES OUT, ESPECIALLY AS A YOUNG WOMAN I WAS VERY SCARRED FOR MY LIFE TO THIS DAY I HAVE NIGHTMARES, GOT IT FIXED BUT NO REALLY CAUSE IT STILL DOES IT WE JUST HAVE TO KEEP PUTTING DOT 3 AT THE CLUTCH LINE. ITS ANNOYING, A WASTE OF TIME, WASTE OF MY MONEY, AND HAS CAUSED DOMESTIC DISPUTES. COME ON DO SOMETHING PLEASE!! *TR

NHTSA ODI #10703449

122,317 miles · Jul 5, 2014
Power Train

I WAS DRIVING MY -2004 CAVALIER AFTER HAVING THE SLAVE CYLINDER REPLACED 2 MONTH'S PRIOR. NOTHING SEEMED OUT OF PLACE UNTIL MY CLUTCH PEDDLE WENT TO THE FLOOR AND DID NOT RETURN. I PULLED OVER AFTER NEARLY COLLIDING WITH ANOTHER VEHICLE INVESTIGATING THE POTENTIAL PROBLEM. I LOOKED IN THE CLUTCH RESERVOIR AND NOTICED NO FLUID. I…

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I WAS DRIVING MY -2004 CAVALIER AFTER HAVING THE SLAVE CYLINDER REPLACED 2 MONTH'S PRIOR. NOTHING SEEMED OUT OF PLACE UNTIL MY CLUTCH PEDDLE WENT TO THE FLOOR AND DID NOT RETURN. I PULLED OVER AFTER NEARLY COLLIDING WITH ANOTHER VEHICLE INVESTIGATING THE POTENTIAL PROBLEM. I LOOKED IN THE CLUTCH RESERVOIR AND NOTICED NO FLUID. I PLACED MORE FLUID IN THE RESERVOIR MANUALLY MOVING THE CLUTCH PEDDLE UP AND DOWN UNTIL I HAD A PEDDLE. I THEN MADE IT HOME SO I COULD FURTHER INVESTIGATE THE PROBLEM. THE LINKAGE FOR THE SHIFTER HAD OVER TIME RUBBED A HOLE IN THE HYDRAULIC CLUTCH LINE CAUSING FAILURE IN THE WHOLE SYSTEM. I AM NOT ONE TO COMPLAIN ABOUT VEHICLE ISSUES BECAUSE MOST OF THE TIME THE ISSUES DO NOT ALMOST KILL ME BUT IN THIS CASE HAD I NOT KNOWN WHAT TO DO TO GET THE SHIFTER OUT OF GEAR I WOULD HAVE HIT A EVER SLOWING LINE OF TRAFFIC AT 70 MPH CAUSING A MASSIVE ACCIDENT. GM PLEASE RECALL YOUR MISTAKE BEFORE YOU KILL MORE PEOPLE WITH YOUR FAULTY CRAFTSMANSHIP. *TR

NHTSA ODI #10608379

150,300 miles · Apr 23, 2014
Power Train

CLUTCH FLUID LEAK FROM SLAVE CYLINDER DETECTED 4/19/14. FLUID LEVEL IN MASTER CYLINDER WAS LOW BUT NOT DANGEROUSLY SO, SO I ADDED DOT-3 TO MASTER CYLINDER. EVENING OF 4/22 NOTICED NO NEW LEAKAGE ON GARAGE FLOOR. ON MORNING OF 4/23 EN ROUTE TO WORK, NOTICED CLUTCH ENGAGED MUCH CLOSER TO FLOOR THAN USUAL, AND HAD MUCH MORE "PLA…

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CLUTCH FLUID LEAK FROM SLAVE CYLINDER DETECTED 4/19/14. FLUID LEVEL IN MASTER CYLINDER WAS LOW BUT NOT DANGEROUSLY SO, SO I ADDED DOT-3 TO MASTER CYLINDER. EVENING OF 4/22 NOTICED NO NEW LEAKAGE ON GARAGE FLOOR. ON MORNING OF 4/23 EN ROUTE TO WORK, NOTICED CLUTCH ENGAGED MUCH CLOSER TO FLOOR THAN USUAL, AND HAD MUCH MORE "PLAY" BETWEEN IT'S NORMAL POSITION AND WHEN CLUTCH BEGAN TO ENGAGE. IN CITY-STREET TRAFFIC, SPEED LIMIT 50 MPH, CLUTCH BEGAN TO SEIZE, CAUSING INABILITY TO SHIFT INTO ANOTHER GEAR. CLUTCH PEDAL TO FLOOR, CAR IN GEAR, RIGHT FOOT OFF GAS, CAR MOVED FORWARD UNDER POWER. TURNED AROUND TO HEAD BACK HOME AND WITHIN TWO MILES CLUTCH WENT BACK TO MOSTLY NORMAL OPERATION. AFTER ANOTHER 3 MILES (THE ENTIRE TRIP WAS ON CITY STREETS WITH SPEED LIMITS BETWEEN 40 AND 55 MPH, INCLUDING LOTS OF STOPLIGHTS=MORE SHIFTING) CLUTCH SEIZED UP ENTIRELY. PEDAL FLAT TO FLOOR, NEEDED TOE UNDER LEVER TO PULL IT BACK UP. STUCK IN 3RD GEAR, NO AMOUNT OF PUMPING THE PEDAL WOULD ALLEVIATE THE PROBLEM. UPON STOPPING, CHECKED FLUID LEVEL IN MASTER CYLINDER AND IT IS SLIGHTLY LOWER THAN WHEN IT WAS FILLED ON 4/19, BUT LEVEL HAD NOT CHANGED IN 24 HOURS. UNABLE TO SHIFT INTO ANY GEAR, CAR WILL NEED TO BE TOWED HOME THEN TO SHOP. *TR

NHTSA ODI #10584436

40,850 miles · Sep 17, 2011
Power TrainUnknown Or Other

REPLACED DEFECTIVE SHIFTER CONTROL CABLE. I HAVE A 2004 CHEVY CAVALIER, 4 CYLINDER ENGINE, MILEAGE: 40,850.I AM THE ORIGNIAL OWNER, PURCHASED IT NEW FROM CHEVROLET. I BECAME AWARE OF THE DEFECT WHEN I CAME OUT OF WORK AND WENT TO MY PARKED CAR, STARTED THE CAR, AND WHEN I SHIFTED MY AUTOMATIC TRANSMISSION LEVER, THE CAR WOULD N…

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REPLACED DEFECTIVE SHIFTER CONTROL CABLE. I HAVE A 2004 CHEVY CAVALIER, 4 CYLINDER ENGINE, MILEAGE: 40,850.I AM THE ORIGNIAL OWNER, PURCHASED IT NEW FROM CHEVROLET. I BECAME AWARE OF THE DEFECT WHEN I CAME OUT OF WORK AND WENT TO MY PARKED CAR, STARTED THE CAR, AND WHEN I SHIFTED MY AUTOMATIC TRANSMISSION LEVER, THE CAR WOULD NOT MOVE. NONE OF THE GEARS WERE WORKING. I HAD TO CALL A TOW TRUCK AND WAIT OVER TWO HOURS AND HAD IT TOWED TO A CHEVROLET DEALER 10 MILES AWAY FOR DIAGNOSIS AND REPAIR. IT COST ME OVER $400.00 TO GET IT REPAIRED BY THE CHEVROLET DEALER. I ASKED CHEVROLET IF THERE WAS A RECALL ON THE SHIFTER CONTROL CABLE AND HE SAID THERE WAS NONE THAT HE KNEW OF. I SEARCHED THE INTERNET FOR SOME INFORMATION ON THE SHIFTER CONTROL CABLE AND FOUND NUMEROUS COMPLAINTS ON THE SAME THING HAPPENING TO THEM WITH THE SAME TYPE CAR. THIS CAR SHOULD BE RECALLED BY GENERAL MOTORS - CHEVROLET DIVISION. THIS IS A VERY DANGEROUS THING TO HAPPEN TO ANYONE. I COULD HAVE BEEN ON THE ROAD OR PARKED ON A HILL WHICH MIGHT HAVE CAUSED HARM TO ME OR ANY OTHER DRIVER OF MY CAR. *TT

NHTSA ODI #10425840

60,000 miles · Feb 19, 2010
Power TrainCrash

CLUTCH PEDAL STARTED TO STOP SHORT. WHILE DRIVING THROUGH LIGHT SNOW I PRESSED THE PEDAL TO SHIFT GEAR BEFORE A SLIGHT TURN AND INCLINE THE PEDAL STAYED DOWN. THE LACK OF POWER TO THE WHEELS WITHIN 5 SECONDS CAUSED THE VEHICLE TO FISHTAIL AND I WAS NOT ABLE TO CONTROL THE VEHICLE EVEN WHILE TRYING TO BRAKE AND GO INTO THE SPIN T…

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CLUTCH PEDAL STARTED TO STOP SHORT. WHILE DRIVING THROUGH LIGHT SNOW I PRESSED THE PEDAL TO SHIFT GEAR BEFORE A SLIGHT TURN AND INCLINE THE PEDAL STAYED DOWN. THE LACK OF POWER TO THE WHEELS WITHIN 5 SECONDS CAUSED THE VEHICLE TO FISHTAIL AND I WAS NOT ABLE TO CONTROL THE VEHICLE EVEN WHILE TRYING TO BRAKE AND GO INTO THE SPIN TO CORRECT. THE VEHICLE SPUN AROUND GOING BACKWARDS THEN THE FRONT END TRIED SWINGING BACK AND HIT THE CENTER MEDIAN DAMAGING THE FRONT END-BUMPER RIPPED OFF, REINFORCEMENT BENT/FOLDED, FENDERS WARPED, BOTH HEADLIGHTS BROKEN, CONDENSER SLIGHTLY FOLDED TO LEAK, RADIATOR SUPPORT WARPED, FRAME BENT. THE SLAVE CYLINDER WAS LEAKING...AGAIN THIS WAS THE SECOND TIME. PEDAL WOULD START TO STOP SHORT THEN THE SLAVE WOULD START TO LEAK. FIRST TIME THE DEALER REPLACED THE SLAVE AND EVERYTHING WAS WORKING. THEN THIS HAPPENED. I WAS TOLD THAT BECAUSE THE SECOND INCIDENT WAS "JUST OUT OF THE REPAIR WARRANT BY 800 MI THEY-THE DEALER- WAS "LIABLE FOR NOTHING" AND WOULD DO NOTHING TO HELP." THE VEHICLE'S SLAVE WAS REPLACED AND EVERYTHING WAS WORKING-WITH THE CLUTCH-WHEN IN 2009 THE PROBLEM HAPPENED AGAIN. I WAS ABLE TO TAKE THE CAR TO THE DEALER AGAIN...AGAIN...AGAIN AND THE MASTER CYLINDER FOR THE CLUTCH WAS REPLACED.-PROBLEM WAS SOLVED. HAVE NOT HAD A PROBLEM SINCE......THIS WHOLE ISSUE SHOWS THAT THE VEHICLE WAS NOT PROPERLY DIAGNOSED WHICH CAUSED THE SECOND FAILURE AND THE ACCIDENT. *TR

NHTSA ODI #10312149

93,000 miles · Aug 17, 2009
Power Train

THIS IS THE SECOND PROBLEM I'VE HAD WITH THIS. CLUTCH PROBLEMS DUE TO A FAULTY HYDRAULIC LINE IN A 2004 CHEVY CAVALIER. FIRST INCIDENT OCCURRED MAY 1ST WHEN THE MASTER TO SLAVE HYDRAULIC HOSE SPLIT OPEN (WAS TOLD BY THE ASE CERTIFIED REPAIR PERSON THIS SHOULD NEVER HAVE HAPPENED). THIS WAS A DEALER ONLY PART AND THERE ARE NO USE…

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THIS IS THE SECOND PROBLEM I'VE HAD WITH THIS. CLUTCH PROBLEMS DUE TO A FAULTY HYDRAULIC LINE IN A 2004 CHEVY CAVALIER. FIRST INCIDENT OCCURRED MAY 1ST WHEN THE MASTER TO SLAVE HYDRAULIC HOSE SPLIT OPEN (WAS TOLD BY THE ASE CERTIFIED REPAIR PERSON THIS SHOULD NEVER HAVE HAPPENED). THIS WAS A DEALER ONLY PART AND THERE ARE NO USED PARTS AVAILABLE FOR THIS. NOW THERE ARE NO LEAKS, BUT CLUTCH STILL STICKS TO THE FLOOR. DRIVING FINE, THEN NO CLUTCH TO PUT CAR INTO CORRECT GEAR. HAD HAPPENED INTERMITTENTLY, BUT TODAY I WAS IN THE MIDDLE OF MORNING RUSH HOUR TRAFFIC. ALMOST CAUSED SEVERAL ACCIDENTS WHEN CAR STALLED AFTER IDLING REALLY LOW. SHUT OFF CAR WHILE SITTING AT A RED LIGHT-- FINALLY AFTER A FIGHT WITH THE STICKSHIFT, GOT INTO GEAR SO I COULD GET TO A PARKING LOT. AFTER LOOKING ON-LINE FOR SOLUTIONS AND A CLOSER REPAIR SHOP, REALIZING THIS HAPPENS QUITE A BIT TO OWNERS. I'M SCARED TO HAVE MY 4 MONTH OLD DAUGHTER IN MY CAR AND WOULD RATHER HAVE HER IN A 1988 MAZDA THAT THE SEATBELTS DON'T CLICK BACK. THIS IS A VERY DANGEROUS PROBLEM AND SHOULD BE ADDRESSED IMMEDIATELY SINCE IT HAPPENS DURING NORMAL DRIVING. IF I WOULDN'T HAVE HAD SOME QUICK THINKING ON MY PART, I PROBABLY WOULD BE IN THE HOSPITAL RIGHT NOW. *TR

NHTSA ODI #10280611

40,000 miles · Jan 21, 2009
Power TrainTires

WHILE DRIVING IN MY CAR ONE DAY I INTENDED TO SHIFT INTO 3RD GEAR, BUT IT ONLY MADE A GRINDING NOISE. I CAN ONLY ASSUME SINCE THE NOISE PERSISTS EVEN WITH REV MATCHING THAT ITS A SYNCRO/CONE PROBLEM. I TRY TO SHIFT DURING THE PROPER RPM AREA, AND SOMETIMES IT WILL SHIFT WITHOUT A PROBLEM OTHER TIMES IT GRINDS. I HAVE NO IDEA …

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WHILE DRIVING IN MY CAR ONE DAY I INTENDED TO SHIFT INTO 3RD GEAR, BUT IT ONLY MADE A GRINDING NOISE. I CAN ONLY ASSUME SINCE THE NOISE PERSISTS EVEN WITH REV MATCHING THAT ITS A SYNCRO/CONE PROBLEM. I TRY TO SHIFT DURING THE PROPER RPM AREA, AND SOMETIMES IT WILL SHIFT WITHOUT A PROBLEM OTHER TIMES IT GRINDS. I HAVE NO IDEA WHY. IT HAD APPROXIMATELY 45,000 MILES ON IT THEN, NOW AROUND 70,000, STILL HAS THE ISSUE. *TR

NHTSA ODI #10255854

58,000 miles · Nov 26, 2008
Power Train

MY 2004 CAVALIER HAS HAD TWO MASTER/SLAVE CYLINDERS TO FAIL. CLUTCH GOES TO THE FLOOR FAILING TO RELEASE THE CLUTCH PEDAL. DEALER TRIED TO CHARGE ME $800 WHEN I HAD WARRANTY. ALMOST CAUSED ACCIDENT BECAUSE OF THIS. VERY UNPROFESSIONAL SERVICE ADVISORS. WILL NEVER RECOMMEND A GM- CHEVROLET VEHICLE TO ANYONE EVER. GM = NIGHTM…

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MY 2004 CAVALIER HAS HAD TWO MASTER/SLAVE CYLINDERS TO FAIL. CLUTCH GOES TO THE FLOOR FAILING TO RELEASE THE CLUTCH PEDAL. DEALER TRIED TO CHARGE ME $800 WHEN I HAD WARRANTY. ALMOST CAUSED ACCIDENT BECAUSE OF THIS. VERY UNPROFESSIONAL SERVICE ADVISORS. WILL NEVER RECOMMEND A GM- CHEVROLET VEHICLE TO ANYONE EVER. GM = NIGHTMARE. DON'T BUY GM EVER!!!! *TR

NHTSA ODI #10249893

36,000 miles · Nov 4, 2008
Power Train

MY 2004 CHEVY CAVALIER WAS PURCHASED MAY 2004 NEW OFF THE LOT. SINCE THEN, MY CLUTCH SYSTEM HAS HAD TO BE REPLACED ALMOST EVERY YEAR. IT FIRST STOPPED WORKING AT 36,000 MILES, JUST 6,000 AFTER FACTORY WARRANTY RAN OUT. IT THEN STOPPED WORKING AGAIN WHILE STILL UNDER PART WARRANTY WHICH LASTS 12,000 MILES. IT AGAIN STOPPED WO…

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MY 2004 CHEVY CAVALIER WAS PURCHASED MAY 2004 NEW OFF THE LOT. SINCE THEN, MY CLUTCH SYSTEM HAS HAD TO BE REPLACED ALMOST EVERY YEAR. IT FIRST STOPPED WORKING AT 36,000 MILES, JUST 6,000 AFTER FACTORY WARRANTY RAN OUT. IT THEN STOPPED WORKING AGAIN WHILE STILL UNDER PART WARRANTY WHICH LASTS 12,000 MILES. IT AGAIN STOPPED WORKING JUST A FEW THOUSAND MILES AFTER THAT WARRANTY RAN OUT. AND NOW HAS GONE OUT FOR THE FOURTH TIME IN UNDER 3,000 MILES. I CAN ALWAYS TELL WHEN THE SYSTEM IS BECOMING FAULTY AFTER ONLY A FEW THOUSAND MILES, HOWEVER DUE TO THE FACT THAT LABOR IS NOT INCLUDED IN ANY WARRANTY, I DRIVE IT UNTIL THE CLUTCH SYSTEM STOPS WORKING. THIS HAS NOT BEEN OF ANY BENEFIT TO ME OR MY CAR. HOWEVER, I SHOULD NOT HAVE TO BE REPLACING ANY PART(S) THIS OFTEN, SO I SHOULD NOT HAVE TO WORRY IN THE FIRST PLACE. THE ANSWER I GET TO WHAT THE PROBLEM IS ALWAYS THE SAME, THE SLAVE CYLINDER O RING IS "LEAKING LIKE A SIV" AND THE MASTER CYLINDER HAS GONE OUT. AND DUE TO THESE TWO ISSUES, IT EFFECTS THE QUALITY OF MY CLUTCH FLY WHEEL. I SEE NO END IN SIGHT FOR THIS PROBLEM, I CAN NOT EVEN GET REBUILT PARTS FOR THIS PROBLEM TO SAVE MYSELF MONEY AND AS STATED BEFORE, LABOR WILL NEVER BE COVERED UNDER WARRANTY. I HAVE NOW PAID FOR HALF THE PURCHASE PRICE OF MY CAR IN PARTS AND LABOR AS IT WAS NEW OFF THE LOT. THIS LEMON OF A CAR IS COSTING ME WELL OVER $1,100 EVERY YEAR IN REPAIRS TO THE CLUTCH SYSTEM AND I CAN NOT AFFORD IT ANY MORE. I HAVE NOT HEARD YET WHAT CUSTOMER SERVICE FOR CHEVY IS GOING TO DO FOR THIS BUT I FELT THAT THIS WAS WORTH YOU HEARING ABOUT SO AS TO HELP OTHERS AFTER ME WHO MAY HAVE THE SAME PROBLEM AND TO ALSO HELP ME WITH MY CURRENT PROBLEM. *TR

NHTSA ODI #10247640

Official recalls

1

04V300000 · 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

0

No exact-year investigations in this snapshot.