2004 Chevrolet Malibu Maxx

GM designed the MY 2004 and 2005 Chevrolet Malibu and Malibu Maxx vehicles with a daytime running lamp (DRL) system that uses the same filament (the high power filament of a dual filament bulb) as the front turn signals.The high power filament operates at full battery voltage when functioning as a DRL.The DRL is illuminated whenever the headlamps are off, increasing the duty cycle of the front turn signal bulb.The MY 2003 and earlier Malibu vehicles (Malibu Maxx was not manufactured for sale in the U.S. prior to MY 2004) used a headlamp based design, operated at a reduced voltage, for the DRL function; GM reverted back to this design on the MY 2006 and later Malibu and Malibu Maxx vehicles. Filament based bulbs have a finite life (hours of illumination) for any given operating voltage.As a result, increasing the duty cycle of a bulb typically decreases the life span of the bulb.GM identified and addressed two front turn signal/DRL and rear turn signal bulb quality issues early in MY 2004 production, however vehicle warranty claims for failed bulbs continued to occur.To address the high warranty levels of bulb failures (90% of the warranty claims submitted to ODI by GM were bulb failures and 10% were socket failures), GM issued a technical service bulletin in March 2006 advising dealers to use a new specification of bulb when addressing service failures, and to also inspect the electrical sockets for thermal damage and replace if necessary.In June 2006 (after subject vehicle production ended) GM changed the turn signal bulb specification to that of the TSB bulb in vehicle production also.To date, ODI has not identified any allegations of crash, injury, or fire related to the alleged defect even though the subject vehicles have experienced 5 - 6 years of field exposure.ODI's analysis of consumer complaints, both VOQ and manufacturer, shows a declining trend.The warranty rate for turn signal bulb replacement is high however statistical analysis of the warranty data suggests that the majority of the original equipment bulbs have already been replaced.GM conducted a safety recall (06V-263) for MY 2004-2005 Cadillac XLR to replace the front turn signal/DRL bulbs and the electrical sockets.However GM advised that the turn signal/DRL bulbs/sockets on the subject vehicles differ from those on the recalled XLRs in several respects, including using bulb sockets with four electrical terminals as opposed to three, which improves the electrical connection, allows the bulb to operate at a lower temperature, and adds stability to the bulb in the socket; operating at a lower voltage, which increases vehicle bulb life; using vented headlamps, which allows bulbs to run cooler than those installed in a non-vented XLR headlamp; and using a clear bulb, which runs cooler than the amber bulbs installed on the XLR.Additionally, the warranty claim level related to subject vehicle sockets is unremarkable compared to other defect investigations into defective socket assemblies.A safety-related defect trend has not been identified at this time.Further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will take further action if warranted by the circumstances.See attached report for further information.

THE SUBJECT VEHICLES MAY EXPERIENCE LOSS OF FUNCTION OF ONE OR MORE OF THE PARK, TURN, STOP OR DAYTIME RUNNING LAMPS (DRL).FAILURE OF THE BULB MAY ALSO INCLUDE DISCOLORATION (HEAT DAMAGE) TO THE BULB SOCKET.GENERAL MOTORS (GM) TECHNICAL SERVICE BULLETIN (TSB) NUMBER 06-08-42-004C INSTRUCTS TECHNICIANS TO EXAMINE THE LAMP HOUSING FOR SIGNS OF DISCOLORATION AND TO REPLACE THE BULBS AND OR SOCKETS DEPENDING ON THE SEVERITY OF THE DISCOLORATION AND THE CONDITION OF THE BULBS AND SOCKETS.THE SCOPE OF INVESTIGATION IN THE PRELIMINARY EVALUATION (PE08-062) WAS THE 2004 MALIBU/MAXX.HOWEVER, THE AGENCY EVALUATED GM'S WARRANTY DATA WHICH INDICATES THAT THE 2005 MODEL YEAR (MY) MALIBU AND MALIBU MAXX VEHICLES ARE ALSO AFFECTED BY THIS CONDITION.THIS INVESTIGATION IS UPGRADED TO AN ENGINEERING ANALYSIS (EA09-004).

IN PERFORMING THIS ENGINEERING ANALYSIS, ODI DETERMINED THAT THE ELECTRIC POWER STEERING SYSTEM IN THE SUBJECT VEHICLES CAN MALFUNCTION OR FAIL, CAUSING THE DRIVER TO LOSE POWER STEERING ASSISTANCE; HOWEVER, DUE TO THE FOLLOWING REASONS, ODI HAS DECIDED THAT FURTHER EXPENDITURE OF AGENCY RESOURCES ON THIS INVESTIGATION IS NOT WARRANTED AT THIS TIME: - GM ISSUED CUSTOMER SATISFACTION CAMPAIGN (CSC) 04050A INDECEMBER 2004 TO ADDRESS THE ALLEGED DEFECT IN APPROXIMATELY58,700 SUBJECT VEHICLES, ENCOMPASSING AT LEAST 97 PERCENT OF THECOMPLAINT AND WARRANTY CLAIMS POPULATION.VEHICLES OUTSIDE THECSC 04050A POPULATION CONTAIN A NEWLY DESIGNED TORQUE ANDPOSITION SENSOR AND HAVE EXPERIENCED A RELATIVELY LOW COMPLAINTRATE.THIS CUSTOMER SATISFACTION CAMPAIGN PRESENTLY HAS ACOMPLETION RATE OF 52%. - THE IMPACT ON THE DRIVER?S ABILITY TO CONTROL THESE RELATIVELYSMALL AND LIGHT VEHICLES WAS LIMITED.VRTC TEST ENGINEERS WEREUNABLE TO INDUCE A FAILURE MODE THAT WOULD CAUSE THE EPS TOSUBSTANTIALLY LIMIT THE DRIVER?S ABILITY TO TURN THE VEHICLE IN APARTICULAR DIRECTION OR TO PROVIDE THE DRIVER WITH UNINTENDEDPOWER ASSISTANCE.- THERE IS NO RISK OF FIRE.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED BY THE CIRCUMSTANCES.(FOR FURTHER DETAILS SEE ATTACHED ENGINEERING ANALYSIS (EA04-018)CLOSING REPORT.)

ODI OPENED PE04-031 BASED ON EIGHT REPORTS OF ALLEGED POWER STEERING FAILURE IN THE SUBJECT VEHICLES.THE COMPLAINTS ALLEGE THAT THE DRIVER SUDDENLY LOST ALL ELECTRIC POWER STEERING ASSISTANCE WITHOUT WARNING MAKING THE VEHICLE DIFFICULT TO STEER. THE SUBJECT VEHICLE UTILIZES AN ELECTRIC POWER STEERING ASSIST SYSTEM (EPS) THAT PROVIDES VARIABLE STEERING ASSISTANCE BASED ON STEERING WHEEL TORQUE, STEERING WHEEL POSTION, AND VEHICLE SPEED.GENERAL MOTORS DOCUMENTS IDENTIFIED THE FOLLOWING TWO FACTORS THAT CONTRIBUTED TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES: A.CONTAMINATION OF THE TORQUE AND POSITION SENSOR FROM THESEPARATION OF GREASE APPLIED TO THE STEERING COLUMN ASSEMBLY. B.ELECTRICAL NOISE GENERATED ON THE POWER AND GROUND SLIP RING SURFACES OF THE TORQUE AND POSITION SENSOR.THE NOISE IS GENERATED AS THE SENSOR CONTACT BRUSHES MOVE ALONG THE SLIP RING SURFACES WHEN THE STEERING WHEEL IS ROTATED.ODI'S ANALYSIS SHOWED FAILURERATES THAT ARE OF CONCERN TO ODI AND INDICATED THAT THE ALLEGED DEFECT IS CONTINUING TO OCCUR IN THE SUBJECT VEHICLES. THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER INVESTIGATE THIS CONCERN, TO ASSESS THE POTENTIAL SAFETY-RELATED CONSEQUENCES, AND TO DETERMINE THE SCOPE OF THE AFFECTED POPULATION.

The contact owns a 2004 Chevrolet Malibu Maxx. The contact stated that after he turned off and restarted the vehicle, the air bag warning light illuminated. The vehicle was taken to Bruce’s auto body shop where it was diagnosed that the air bag side impact sensor failed to reset and needed to be replaced. The vehicle was not repaired. The manufacturer was notified by the dealer and the contact was informed that the parts were no longer being manufactured and was unavailable. The failure mileage was approximately 164,000.

NHTSA ID

11523825

Incident

Jan 18, 2023

Mileage

164,000 mi

The contact owns a 2004 Chevrolet Malibu. The contact stated while driving 50 MPH, the vehicle experienced a loss of power steering assist. The contact related the failure to NHTSA Campaign Number: 14E044000 (Steering) however, the VIN was not included. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 160,000.

NHTSA ID

11521181

Incident

May 9, 2022

Mileage

160,000 mi

The contact owns a 2004 Chevrolet Malibu Maxx. The contact stated while driving approximately 30 MPH, the vehicle lost power steering functionality. The power steering warning light was illuminated. The vehicle was taken to an independent mechanic and diagnosed with power steering failure. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 117,000.

NHTSA ID

11463018

Incident

May 1, 2022

Mileage

117,000 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. THE CONTACT STATED THAT WHILE MAKING A LEFT TURN THE VEHICLE SHIFTED INTO NEUTRAL INDEPENDENTLY WITHOUT WARNING. THE CONTACT DEPRESSED THE BRAKE PEDAL TO STOP THE VEHICLE. THE CONTACT ATTEMPTED TO MANUALLY SHIFT THE VEHICLE INTO PARK HOWEVER, THE TRANSMISSION FAILED TO ENGAGE. THE CONTACT PUSHED THE VEHICLE OVER TO THE SIDE OF THE ROADWAY. THE VEHICLE WAS TOWED TO MIDWAY CHEVROLET (2323 W BELL RD, PHOENIX, AZ) WHERE IT WAS DIAGNOSED AND DETERMINED THAT THE TRANSMISSION FAILED AND NEEDED TO BE REPLACED. THE CONTACT MENTIONED NHTSA CAMPAIGN NUMBER: 14V224000 (POWER TRAIN) AS A POSSIBLE SOLUTION TO THE FAILURE, HOWEVER THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS CONTACTED HOWEVER, NO FURTHER ASSISTANCE WAS PROVIDED. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000.

NHTSA ID

11329336

Incident

Apr 10, 2018

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. WHILE DRIVING APPROXIMATELY 60 MPH, THE STEERING ABILITY SEIZED AND ALL THE WARNING INDICATORS ILLUMINATED. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD AS THE POWER STEERING WARNING INDICATOR REMAINED ILLUMINATED. THE VEHICLE WAS DRIVEN TO THE CONTACT'S RESIDENCE AND THEN TO MCCURLEY CHEVROLET (1325 N AUTOPLEX WAY, PASCO, WA 99301) WHERE IT WAS DETERMINED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 14V153000 (STEERING). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.

NHTSA ID

11229332

Incident

May 20, 2019

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU MAXX. WHILE OPERATING THE VEHICLE, THE POWER STEERING MALFUNCTIONED AND THE STEERING WHEEL BECAME VERY DIFFICULT TO TURN IN EITHER DIRECTION. ALSO, 'POWER STEERING' DISPLAYED ON THE INSTRUMENT PANEL. THE VEHICLE WAS DRIVEN TO BILLION AUTOMOTIVE (600 W. 41ST, SIOUX FALLS, SD) WHERE IT WAS DIAGNOSED THAT THE TORQUE SENSOR WAS FAULTY AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE BUT NO ASSISTANCE WAS OFFERED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 125,000.

NHTSA ID

11205826

Incident

May 1, 2019

Mileage

125,000 mi

NO STEERING,STEERING TURNS AROUND AND AROUND WITHOUT STOP TURNING IN EITHER DIRECTION,RIGHT OR LEFT. SECOND TIME THIS HAPPENED,SPENT APPROXIMATELY $1200.00 BEFORE. CAR THIS TIME ENDED IN A TOW POUND YARD. TRIPLE AAA MOVED MY CAR TO A SHOP CALLED QUICK STOP WHERE I WANTED TO GET MY CAR FIXED AT ONLY TO DISCOVER THEY DIDN'T DO ELECTRICAL WORK WHICH THEY DISCOVERED WAS THE PROBLEM AMONG OTHERS. AGAIN THE TOWING COMPANY TRIPLE AAA CARRIED IT TO WEBB CHEVROLET SUGGESTED BY THIS SHOP. WEBB CHEVROLET DISCOVERED ALSO ELECTRICAL ISSUES. MY INSURANCE NOTIFIED ME AFTER I CONTACT THEM FOR A CLAIM REPORT. AN ESTIMATOR WAS SENT TO WEBB CHEVROLET ALSO THEY DISCOVERED AFTER A TEAR DOWN DIAGNOSIS THAT IT IS A RECALL ISSUES. NOW YOU ARE BEING NOTIFIED BY ME,RUBY WELLS OF THESE PROBLEMS. THIS IS WHY IM NOTIFYING YOU OF THE RECALLS FOUND ON THIS MAKE,MODEL AND YEAR 2004 VEHICLE. NOT STATIONARY,IT WAS IN MOTION WHEN HAPPENED ON CITY STREET. MY SON WAS ARRESTED FOR NO REASON $2000 BAIL TIMES 2 . COURT JUDGE THROUGH CASE OUT ON APRIL 45TH 2019 AFTER DISCOVERING BOGUS TICKETS WRITING AND ARRESTS THEY INDICATED THERE WAS NO INSURANCE ON VEHICLE AND HAD MY CAR TOWED TO POUND WITHIN HOURS. I HAD TO PAD TOWING FEES OF $1200 APPROXIMATELY TO GET MY CAR FROM POUND LESS THAN24 HOURS OF THE TOWING. MONEY HAS ALREADY BEEN SPENT UNNECESSARILY MONEY I HAD TO BORROW BECAUSE I'M RETIRED. PLEASE TAKE CARE OF THIS FOR ME ASAP. PLEASE!

NHTSA ID

11194247

Incident

Mar 7, 2019

Mileage

155,000 mi

STEERING OUT OF WHACK. I HAVE HAD MY CONTROL ARM ON BOTH SIDES CHANGED ALONG WITH AXLES AND A ALIGNMENT. NO LUCK ITS STILL ALL OVER ROAD. I DRIVE FROM SYLVESTER GA TO TIFTON GA EVERYDAY. IT DOES THE SAME THING EVERYTIME. ALSO I HAVE HAD MY LIGHTS REPLACED 3 TIMES IN THE LAST YEAR. WHY ARENT THE LASTING. GAS CAP KEEPS READING ERROR. WHOLE CAR. I CAN LET SOMEONE DRIVE IT TO SEE WHAT I AM SAYING.

NHTSA ID

11193420

Incident

Jan 1, 2019

Mileage

140,000 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.