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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

What owners actually said

330 reports
76,000 miles · Jul 12, 2007
Fuel System, Other

ON 2004 CHEVROLET CAVALIER FUEL PUMP WENT OUT A TONLY 76000 MILES. BEEN HAVING PROBLEMS IDLING. *AK

NHTSA ODI #10196231

Mileage unknown · Apr 12, 2007
Electrical System

CLUSTER IN DASH FAILED, NO GAUGES WORK. *AK

NHTSA ODI #10187680

35,000 miles · Dec 4, 2006
Seat Belts

DT*: THE CONTACT STATED THE PLASTIC HOUSING ON BOTH REAR OUTER SEAT BELTS FRACTURED AND DETACHED. THE SEAT BELTS ALSO DID NOT HOLD THE OCCUPANTS SECURELY. THE VEHICLE WAS TAKEN TO A SERVICE DEALER, WHERE THE DEALER DETERMINED THAT THE PROBLEM WAS CAUSED BY NORMAL WEAR AND TEAR. THE MANUFACTURER WAS ALSO NOTIFIED.

NHTSA ODI #10175103

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

43,000 miles · Oct 19, 2006
Visibility

DT*: THE CONTACT STATED THE FRONT LEFT AND RIGHT REAR POWER WINDOWS WERE FAILING. THE SERVICE DEALER REFUSED TO CLOSE THE WINDOW WITHOUT CHARGING FOR THE SERVICE. THE MANUFACTURER WAS NOTIFIED.

NHTSA ODI #10171320

70,455 miles · Sep 22, 2006
Steering

2004 CHEVY CAV. NEEDS NEW RACK AND PINION STEERING ASSEMBLY. WAS TOLD BY MECH THAT HE HAD TO REPLACE 3 OTHER CAV'S RACK AND PINION SYSTEMS DUE TO MALFUNCTIONS. WHAT IS THE DEAL WITH THESE RACK SYSTEMS. I HAVE 70555 MILES ON MY CAR. WAS TOLD BY MECH THAT CAV'S WITH LESSER MILEAGE NEEDED REPLACING. MECH SAID THIS SYSTEM NEEDS TO B…

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2004 CHEVY CAV. NEEDS NEW RACK AND PINION STEERING ASSEMBLY. WAS TOLD BY MECH THAT HE HAD TO REPLACE 3 OTHER CAV'S RACK AND PINION SYSTEMS DUE TO MALFUNCTIONS. WHAT IS THE DEAL WITH THESE RACK SYSTEMS. I HAVE 70555 MILES ON MY CAR. WAS TOLD BY MECH THAT CAV'S WITH LESSER MILEAGE NEEDED REPLACING. MECH SAID THIS SYSTEM NEEDS TO BE LOOKED AT. AND SHOULD BE FIXED BY CHEVY. *NM

NHTSA ODI #10168991

25,250 miles · Sep 19, 2006
Vehicle Speed Control

VEHICLE'S IDLE STUCK AT 2500 RPM'S, MAKING IT DIFFICULT TO BRAKE. OTHER TIMES VEHICLE'S RPM'S ARE SO LOW THE VEHICLE STALLS. WHEN THEY ARE TOO HIGH THE ONLY CORRECTION IS TO ENGAGE THE CLUTCH AND TURN THE VEHICLE OFF. CHEVY DEALERS CAN'T DUPLICATE THE PROBLEM, SO THEY DO NOTHING. THE PROBLEM IS INTERMITTENT. *NM

NHTSA ODI #10168681

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

Mileage unknown · Aug 6, 2006
Electrical SystemEngine And Engine Cooling

WHILE DRIVING MY CAR, THE ENGINE WOULD COMPLETELY SHUT OFF. AT FIRST IT WOULD HAPPEN WHEN I WAS AT A COMPLETE STOP. HOWEVER IT BEGAN TO HAPPEN WHILE THE CAR WAS IN MOVEMENT. I TRIED TO CRANK THE CAR TO TAKE IT TO THE SHOP AND IT WOULDN'T CRANK AT ALL. THE PROBLEM COULDN'T BE IDENTIFIED ON A DIAGNOSTIC TEST AND IT WASN'T THE …

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WHILE DRIVING MY CAR, THE ENGINE WOULD COMPLETELY SHUT OFF. AT FIRST IT WOULD HAPPEN WHEN I WAS AT A COMPLETE STOP. HOWEVER IT BEGAN TO HAPPEN WHILE THE CAR WAS IN MOVEMENT. I TRIED TO CRANK THE CAR TO TAKE IT TO THE SHOP AND IT WOULDN'T CRANK AT ALL. THE PROBLEM COULDN'T BE IDENTIFIED ON A DIAGNOSTIC TEST AND IT WASN'T THE SPARK PLUGS. I WAS TOLD TO REPLACE THE COMPUTER TO SEE IF THAT WAS THE PROBLEM. THE AUTO SHOP WAS NOT EVEN SURE THAT IT WAS THE PROBLEM. THIS COMPUTER COST $650 NOT INCLUDING LABOR. NOW MY ENGINE LIGHT CONTINUALLY FLASHES AND THE CAR JERKS. HOWEVER WHEN I TAKE IT TO THE AUTO SHOP THEY SAY THAT I HAVE GOTTEN BAD GAS. THEY CAN'T FIND ANOTHER PROBLEM. I'VE CHANGED WHERE I GET MY GAS AND IT STILL HAPPENS DAILY. OUT OF 3 HOURS OF DRIVING IT MAY RUN NORMALLY ABOUT 1- 1.5 HOUR. *NM

NHTSA ODI #10164658

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.