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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.

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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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Mileage unknown · Aug 21, 2008
Power Train

DRIVING HOME FROM WORK THROUGH CITY STREETS AND SUDDENLY WAS NOT ABLE TO DISENGAGE CLUTCH WHEN ATTEMPTING TO SHIFT FROM 2ND TO THIRD. TRANSMISSION STUCK IN 2ND. LUCKILY I WAS ONLY A COUPLE MILES FROM HOME. FURTHER INVESTIGATION ON MY PART FOUND CLUTCH HYDRAULIC HOSE HAD HOLE WORN INTO IT DUE TO BRACKET LOCATION. POOR DESIGN WITH…

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DRIVING HOME FROM WORK THROUGH CITY STREETS AND SUDDENLY WAS NOT ABLE TO DISENGAGE CLUTCH WHEN ATTEMPTING TO SHIFT FROM 2ND TO THIRD. TRANSMISSION STUCK IN 2ND. LUCKILY I WAS ONLY A COUPLE MILES FROM HOME. FURTHER INVESTIGATION ON MY PART FOUND CLUTCH HYDRAULIC HOSE HAD HOLE WORN INTO IT DUE TO BRACKET LOCATION. POOR DESIGN WITH RESPECT TO HOSE CONFIGURATION AND BRACKET LOCATION. HIGH POTENTIAL FOR PERSONAL INJURY WHEN OPERATING. *TR

NHTSA ODI #10239176

100,137 miles · Aug 10, 2008
Power TrainCrash

WHEN I WAS DROPPING MY SISTER OFF AT THE AIRPORT, I WAS LEAVING IN MY CAVALIER WHICH IS A MANUAL TRANSMISSION I PUT THE CAR IN REVERSE AND ENGAGED THE CLUTCH IT STUCK ON AND WOULD NOT COME OFF. I HAD TO SLAM ON THE EMERGENCY BRAKE AND BRAKES TO STALL OUT THE CAR. ONCE THE CAR STALLED IT ALSO CAME TO REST AGAINST A TREE, WHICH TH…

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WHEN I WAS DROPPING MY SISTER OFF AT THE AIRPORT, I WAS LEAVING IN MY CAVALIER WHICH IS A MANUAL TRANSMISSION I PUT THE CAR IN REVERSE AND ENGAGED THE CLUTCH IT STUCK ON AND WOULD NOT COME OFF. I HAD TO SLAM ON THE EMERGENCY BRAKE AND BRAKES TO STALL OUT THE CAR. ONCE THE CAR STALLED IT ALSO CAME TO REST AGAINST A TREE, WHICH THANKFULLY DID NOT CAUSE ANY DAMAGE EXCEPT A FEW SCRATCHES. ON FURTHER INVESTIGATION I HAD NOTICED THAT A HOLE HAS WORN IN THE HYDRAULIC RUBBER LINE FROM THE MASTER CLUTCH CYLINDER. THE HOSE WAS RUBBING AGAINST A WIRING HARNESS METAL BRACE BRACKET JUST BELOW THE CLUTCH MASTER CYLINDER. IT COULD HAVE CAUSED ALOT OF DAMAGE OR PERSONAL INJURY OR EVEN DEATH IN THE RIGHT CIRCUMSTANCES. I HAD JUST LEFT THE HALIFAX WATER FRONT WHERE THERE WERE ABOUT 6000 PEOPLE AND IF THE PROBLEM HAPPENED. THERE COULD HAVE BEEN MAJOR PROBLEMS. I WOULD LIKE SOMEONE TO LOOK INTO THIS PROBLEM. WHEN IT HAPPENED THERE WAS NO WARNING. *TR

NHTSA ODI #10237572

36,000 miles · Jun 23, 2008
Power Train

CLUTCH STARTED FEELING SLUSHY AND THEN FAILED AFTER A FEW MONTHS. CLUTCH STAYS TO THE FLOOR. REPAIR TO BE DONE, REPLACE SLAVE CYLINDER. *TR

NHTSA ODI #10232075

60,000 miles · Nov 6, 2007
Power Train

MY 2004 CAVALIER HAS HAD TWO SLAVE CYLINDERS TO FAIL. CLUTCH GOES TO THE FLOOR FAILING TO RELEASE THE CLUTCH. *TR

NHTSA ODI #10208095

42,000 miles · Sep 4, 2007
Power Train

I HAVE 2004 CHEVY CAVALIER WITH LESS THAN 40K MILEAGE. ON AUGUST 31, 2007, THE CLUTCH PAD SUDDENLY DID NOT BACK UP ON MY WAY HOME. I CHECKED THIS WEBSITE AND FOUND I HAD THE SAME ISSUE AS ANOTHER CONSUMER. ALL THE LIQUID WAS COMING OUT FROM THE CLUTCH LINE BETWEEN MASTER CYLINDER TO TRANSMISSION. WHEN I CHECKED THE LINE, I FOUND…

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I HAVE 2004 CHEVY CAVALIER WITH LESS THAN 40K MILEAGE. ON AUGUST 31, 2007, THE CLUTCH PAD SUDDENLY DID NOT BACK UP ON MY WAY HOME. I CHECKED THIS WEBSITE AND FOUND I HAD THE SAME ISSUE AS ANOTHER CONSUMER. ALL THE LIQUID WAS COMING OUT FROM THE CLUTCH LINE BETWEEN MASTER CYLINDER TO TRANSMISSION. WHEN I CHECKED THE LINE, I FOUND OUT THE CLUTCH LINE WAS TOUCHING THE WIRE BOX CORNER ALL THE TIME. THERE IS A HOLE IN THAT TOUCHING POINT. IT IS VERY CLEAR THAT THIS IS A DESIGN PROBLEM FOR THIS KIND OF CAR. THE GM CHEVY DEALER SAID THE PURCHASED DATE HAD PASSED THREE YEARS. NO WARRANTY AT ALL. WHEN I SEARCH THE WEB FOR HELP. I FOUND THE OTHER PEOPLE COMPLAIN THE SAME PROBLEM TOO. *TR UPDATED 10/24/07. *JB

NHTSA ODI #10201764

Mileage unknown · Aug 14, 2007
Power TrainVehicle Speed Control

I HAVE 2004 CHEVY CAVALIER WITH LESS THAN 24K MILEAGE. ON AUGUST 4, 2007, THE CLUTCH PAD SUDDENLY DID NOT BACK UP ON MY WAY HOME. I CANNOT CHANGE THE SPEED. WHEN AAA GUY CAME TO TOW, HE FOUND OUT THERE WAS NO HYDAULIC LIQUID. I BOUGHT THE LIQUID AND ADDED IT INTO THE HYDRAULIC LIQUID RESERVOIR. WHEN I STARTED MY CAR AND PRESSED…

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I HAVE 2004 CHEVY CAVALIER WITH LESS THAN 24K MILEAGE. ON AUGUST 4, 2007, THE CLUTCH PAD SUDDENLY DID NOT BACK UP ON MY WAY HOME. I CANNOT CHANGE THE SPEED. WHEN AAA GUY CAME TO TOW, HE FOUND OUT THERE WAS NO HYDAULIC LIQUID. I BOUGHT THE LIQUID AND ADDED IT INTO THE HYDRAULIC LIQUID RESERVOIR. WHEN I STARTED MY CAR AND PRESSED THE CLUTCH, THE AAA GUY FOUND ALL THE LIQUID WAS COMING OUT FROM THE CLUTCH LINE BETWEEN MASTER CYCLINDER TO TRANSMISSION. WHEN I CHECKED THE LINE, I FOUND OUT THE CLUTCH LINE WAS TOUCHING THE WIRE BOX CORNER ALL THE TIME. THERE IS A HOLE IN THAT TOUCHING POINT. IT IS VERY CLEAR THAT THIS IS A DESIGN PROBLEM FOR THIS KIND OF CAR. THE GM CHEVY DEALER SAID THE PURCHASED DATE HAD PASSED THREE YEARS. NO WARRANTY AT ALL. WHEN I SEARCH THE WEB FOR HELP. I FOUND THE OTHER PEOPLE COMPLAIN THE SAME PROBLEM TOO. IF YOU NEED MORE DETAIL INFORMATION, I STILL KEEP THE BROKEN PART. I CAN SEND THE PICTURE OR THE BROKEN PART. THANKS, JUN SHEN *TR

NHTSA ODI #10199524

41,000 miles · Nov 6, 2006
Power Train

MY 2004 CHEVROLET CAVALIER HAS LESS THAT 41,000 MILES ON IT. I WAS ABOUT 180 MILES FORM HOME WHEN THE CLUTCH WENT OUT. I WAS TOLD BY THE CHEVROLET DEALERSHIP IN THAT CITY THAT THE CLUTCH CYLINDER, CLUTCH PLATES, AND CLUTCH FLUID NEED TO BE REPLACED. ALSO, THE EXTENDED WARRANTY, WHICH COVERS UP TO 75,000 MILES, DOES NOT COVER "EX…

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MY 2004 CHEVROLET CAVALIER HAS LESS THAT 41,000 MILES ON IT. I WAS ABOUT 180 MILES FORM HOME WHEN THE CLUTCH WENT OUT. I WAS TOLD BY THE CHEVROLET DEALERSHIP IN THAT CITY THAT THE CLUTCH CYLINDER, CLUTCH PLATES, AND CLUTCH FLUID NEED TO BE REPLACED. ALSO, THE EXTENDED WARRANTY, WHICH COVERS UP TO 75,000 MILES, DOES NOT COVER "EXTERNAL PARTS". WHICH IS WHAT THE CLUTCH IS CONSIDERED. IT'S GOING TO COST ME AROUND $1400 TO GET IT FIXED. IN MY OPINION, THE CLUTCH SHOULD NOT HAVE FAILED ON A VEHICLE THIS NEW. HAD I BEEN ON THE FREEWAY OR BUSY STREET, THERE WOULD HAVE BEEN A MAJOR ACCIDENT. I FEEL THAT THIS PROBLEM NEEDS TO BE CONSIDERED A MANUFACTURER DEFECT, NOT NORMAL WEAR AND TEAR...*NM

NHTSA ODI #10172741

5,000 miles · Aug 30, 2006
Electrical SystemEquipmentFuel System, Other

I BOUGHT MY CAR, A 2004 CHEVY CAVALIER WITH 21 MILES ON IT. SINCE THEN I HAVE TRIED TO RETURN IT AND NOW THE MINOR BUT FREQUENT ISSUES ARE MUCH BIGGER AND MORE FREQUENTLY! FIRST MY TRUNK LATCH BROKE A WEEK AFTER PURCHASE. THE CD BROKE THE NEXT WEEK, CIGARETTE LIGHTER BROKE, AND PASSENGER SEAT WOULDN'T MOVE. THIS WAS THE FIR…

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I BOUGHT MY CAR, A 2004 CHEVY CAVALIER WITH 21 MILES ON IT. SINCE THEN I HAVE TRIED TO RETURN IT AND NOW THE MINOR BUT FREQUENT ISSUES ARE MUCH BIGGER AND MORE FREQUENTLY! FIRST MY TRUNK LATCH BROKE A WEEK AFTER PURCHASE. THE CD BROKE THE NEXT WEEK, CIGARETTE LIGHTER BROKE, AND PASSENGER SEAT WOULDN'T MOVE. THIS WAS THE FIRST TWO MONTHS OF OWNERSHIP. A FEW MONTHS AGO THE FUEL GAUGE BROKE, TEMP GAUGE AND AC. THEY COULDN'T VERIFY IT SO COULDN'T REPAIR, UNTIL IT COMPLETELY FAILED THIS MONTH. ALSO, I WAS LEFT STRANDED AT 2:30 AM WITH MY 3 YEAR OLD SON WHEN THE CLUTCH FELL THROUGH THE FLOOR. IT WAS REPAIRED AND NOW THE RPMS SHOOT UP TO 6000, IS UNRESPONSIVE TO ANY PEDALS, AND REQUIRES TURNING THE ENGINE OFF. THIS HAPPENED IN SAN FRANCISCO ON HIGHWAY 101, I AM TRULY AFRAID FOR THE SAFETY OF MYSELF. SON, AND OTHERS DRIVING THIS CAR OR NEAR ONE. THERE ARE MANY OTHER UNMENTIONED THINGS THAT HAVE OCCURRED, TOO MANY TO TELL IN THIS SUMMARY. THEY OF COURSE CAN'T DUPLICATE THIS MAJOR PROBLEM AND THEREFORE CAN'T "CORRECT." ALSO THEY STATE IT DOESN'T FALL UNDER LEMON, BUT WHAT IS AT STAKE OUR LIVES. *JB

NHTSA ODI #10167018

45,000 miles · Aug 14, 2006
Power Train

CLUTCH SLAVE CYLINDER FAILED, SLAVE CYLINDER IS INSIDE THE BELL HOUSING. IF THIS HAD HAPPENED IN TRAFFIC IT COULD HAVE CAUSED AN ACCIDENT. *JB

NHTSA ODI #10165395

37,115 miles · May 1, 2006
Power Train

DT*: THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS AND ATTEMPTING TO SHIFT GEARS, THE CLUTCH DID NOT ENGAGE. AFTER SEVERAL ATTEMPTS, THE CLUTCH ENGAGED AND THE GEARS WERE SWITCHED. THE VEHICLE WAS SEEN BY A DEALER AND THE DEALER DETERMINED THE CLUTCH ASSEMBLY OF THE MANUAL TRANSMISSION NEEDED TO BE REPLACED.

NHTSA ODI #10156537

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.