2004 Chevrolet Cavalier Problems
- Complaints
- 330filed with NHTSA
- Median mileage
- 51,931miles, 262 complaints with mileage
- Recalls
- 1campaigns on record
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 27 mpgcombined, 2.2L 4-cyl FWD · 23 city / 33 hwy
Sources: NHTSA records for the 2004 Chevrolet Cavalier (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error
What owners report
Owners of the 2004 Chevrolet Cavalier most often describe instrument cluster problems: the speedometer, tachometer, fuel gauge and temperature gauge give wrong readings, stick, or quit entirely, frequently with well under 60,000 miles on the odometer. Smaller groups of complaints describe window regulators and wipers that stop working, a clutch pedal that goes to the floor, and erratic gauge clusters that owners say were quoted high repair costs at the dealer.
- Electrical system
Speedometer and gauge cluster fail or read wrong
- 171 complaints (52%)
- median 54,050 mi at 5.8 yrs old (140 state mileage)
- 2 mention a crash, fire or injury
- owner-quoted repair $490 (median of 18 quotes)
- filed 2004–2018
Owners describe the speedometer sticking at a speed after slowing down, reading far above or below actual speed, or swinging past the top of the dial; the tachometer and fuel and temperature gauges behave the same way, sometimes all at once. Many say the problem is intermittent at first and then constant. According to the complaints, dealers often quoted several hundred dollars to replace the cluster, and some owners were told the part was not covered or that a related campaign had expired. Reported from roughly 8,000 to 110,000 miles, with many complaints between 25,000 and 60,000 miles.
What to check: With the key on, confirm every gauge rests where it should and test-drive with a GPS speed readout to compare against the speedometer. Ask whether the cluster has ever been replaced or repaired, and keep in mind replacement clusters are commonly sourced used.
2 excerpts from owner complaints in NHTSA records
“The gauges on my Cavalier are all messed up. Sometimes the only gage that works are my RPM gauges. All the other gauges: the gas gage, the thermometer gauges and the MPH gage never work right. I can't tell how fast I am going, how much gas is in the car or if it's going to overheat on me or not. It will not reset. This has been going on for two years.”
NHTSA complaint #10315647, filed 2010-03, 35,000 miles“2004 chevy Cavalier speedometer instrument cluster fails. Speedometer reads incorrect speed and fails. It is very dangerous not knowing how fast you are going, I received a speeding ticket as a result. I replaced the instrument cluster with one from a junk yard. The problem is temporarily fixed. There are many other people with the same issue.”
NHTSA complaint #10369941, filed 2010-12, 32,000 miles - Electrical system
Stalls, no-starts or electrical cutouts linked to ignition
- 68 complaints (21%)
- median 55,900 mi at 5.5 yrs old (54 state mileage)
- 1 mention a crash, fire or injury
- owner-quoted repair $500 (median of 10 quotes)
- filed 2004–2016
Owners describe the engine quitting while driving, sometimes with all warning lamps lighting, and intermittent no-starts where the car turns over briefly and then loses power. In several cases a dealer replaced the ignition switch or a related module after other repairs did not help, and one complaint notes the key had to be cycled to restart. Reported from very low mileage (under 15,000 miles) up to about 90,000 miles.
What to check: Ask whether the ignition switch has been replaced, and note during a test drive whether the engine or electrical accessories cut out when the key or key ring is moved.
2 excerpts from owner complaints in NHTSA records
“As I was driving down the road the vehicle stopped running and I had to pull over to the side of the road. I then tried to start the car again but it did not start. So I tried again a few more time. The vehicle did start so I took the car in for repairs the next week which was my first attempt. It took 2 more visits to get the car fixed correctly. It turned out to be the ignition switch sensor. Just like the recall by GM. But my model is not included, I hope it will be added in the future.”
NHTSA complaint #10574473, filed 2014-03, 72,004 miles“I am concerned because of the ignition recall. For the last several months, at random times, if I touched the keys which were in the ignition, more often than not, the overhead dome light would either flicker or actually go on for several seconds to a minute before shutting off. This is not a result of pulling them so that they are not solidly inserted, but due to being jostled. This has happened when the car is running, or not running, and occasionally when I insert the key in the ignition. …”
NHTSA complaint #10568646, filed 2014-03, 85,000 miles - Visibility (wipers, defrost, mirrors)
Power windows stop working or come off track
- 23 complaints (7%)
- median 42,000 mi at 4.4 yrs old (21 state mileage)
- filed 2004–2015
Complaints describe a window that stops moving without warning, sometimes in the down position, and in some cases a window that comes off its track so air leaks in. Owners report repeat failures on the same door, with repairs done under warranty at first and later quoted at several hundred dollars per window. Mostly reported between about 10,000 and 80,000 miles, often within the first few years of ownership.
What to check: Run every window up and down several times, listen for grinding or slow movement, and check that the glass seals against the weatherstrip when fully up.
2 excerpts from owner complaints in NHTSA records
“The tachometer is failing to work, the speedometer is failing to work, the drivers side window went out, and the service engine light stays on with the ABS and track off lights stay on. This is constant. Now, I am worried that the speedometer will have a problem when I am driving my children. There doesn't seem to be a clear cut fix for this when talking to the chevy dealer.”
NHTSA complaint #10229180, filed 2008-05, 117,000 miles“I have a 2004 Cavalier. Shortly after I bought it the drivers window stopped working. I had a warranty and replaced it. It stopped working without any warning. When I got the car back I could hear air coming through the window, but didn't see any gaps. Eventually noticed the window was off track. My guess is poor fixing by the dealership. About 2 years later (my warranty is up) the drivers window quit working again. I had to drive in the pouring rain with my window down. …”
NHTSA complaint #10339473, filed 2010-06, 42,000 miles - Transmission and drivetrain
Clutch pedal goes to the floor, clutch will not release
- 23 complaints (7%)
- median 45,000 mi at 4.4 yrs old (21 state mileage)
- 2 mention a crash, fire or injury
- owner-quoted repair $800 (median of 5 quotes)
- filed 2004–2020
On manual-transmission cars, owners describe the clutch pedal sinking to the floor and the car refusing to go into gear, sometimes after noticing low fluid in the master cylinder reservoir or a leak at the slave cylinder. Complaints mention repeated master/slave cylinder replacement, and one describes the clutch beginning to seize in traffic so gears could not be selected. Reported from about 42,000 to 150,000 miles.
What to check: On a manual car, check clutch pedal feel and travel and look at the clutch fluid level and for fluid around the slave cylinder; ask whether either cylinder has been replaced.
2 excerpts from owner complaints in NHTSA records
“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!!!!”
NHTSA complaint #10249893, filed 2008-11, 58,000 miles“While driving home from thanksgiving I was unable to shift my manual transmission, and I noticed that the clutch appeared stuck to the floor. The remainder of the way home (30 miles) if I slowed down the would stall as I could not push the clutch in. The car, a 2004 Cavalier, has a total of 42000 miles on it. Upon getting the car to the dealer I was told the master cylinder, the slave.”
NHTSA complaint #10143646, filed 2005-11, 45,000 miles
Buying note. The main thing to verify on a 2004 Cavalier is the instrument cluster: test every gauge against a GPS speed reading and ask about past cluster repairs, since owners frequently describe paying for replacements. On manual cars, also confirm clutch pedal feel and fluid level, and check that all windows, wipers and vent controls work before agreeing on a price.
Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.
NHTSA recorded 330 consumer complaints for the 2004 Chevrolet Cavalier. 262 of the complaints include a mileage, and 44% of those were filed for vehicles with under 50,000 miles; the median is 51,931 miles. Of all complaints, 17 involved a crash, 6 a fire, 19 an injury, 1 a death, according to the filers. NHTSA lists 1 recall campaign and 409 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Electrical system185 56%
- Vehicle speed control27 8.2%
- Transmission and drivetrain23 7.0%
- Steering16 4.9%
- Air bags15 4.5%
- Engine cooling15 4.5%
- Fuel system15 4.5%
- Brakes14 4.2%
- Other or unknown13 3.9%
Also reported: Body and structure (13), Exterior lighting (8), Seats (8), Engine (7), Equipment (6), Seat belts (6), Suspension (6), Latches, locks and linkages (4), Tires (4), Wheels (4), Electronic stability control (2), Interior lighting (1).
Example complaints
Electrical system: “The gauges show nothing no speed no gas no mileage nothing. I have seen a lot of complaints of this matter why is there nothing being done about this problem. I was always a chevy person but now I am moving on to something else. Chevy does not like to fix there problems they leave it up to the people to spend tons of money to fix the prob when they know what the prob is. This is uncalled for.”
NHTSA complaint #10596032, filed 2014-06, 111,000 milesVehicle speed control: “While driving down the road my speedometer for stuck. I know I was going 60 when it happened because that's what it is stuck at.it isn't the first time this has happened. My car has had multiple problems with the windshield wipers, windows, and engine light.”
NHTSA complaint #10691973, filed 2015-03, 58,000 milesVisibility (wipers, defrost, mirrors): “I discovered at 1500 miles my 2004 Cavalier ls had a leak apparent in the roof liner. Took it to the dealer and turns out the rear back window seal was not properly installed and was crimped upon installation at the factory. The problem was repaired under warranty by GM and was fixed to my satisfaction.”
NHTSA complaint #10062531, filed 2004-03, 1,500 milesTransmission and drivetrain: “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!!”
NHTSA complaint #10703449, filed 2015-04, 109,000 milesMileage when problems were reported
44% of the 262 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 35,000 and 85,509 miles.
Complaints by year filed
Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
Crash test ratings
NHTSA's 5-Star Safety Ratings for the 2004 Chevrolet Cavalier. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.
| Version | Overall | Frontal | Side | Side pole | Rollover |
|---|---|---|---|---|---|
| Cavalier · sedan | not rated | 4 / 4 | — | — | — |
| Cavalier · coupe | not rated | 4 / 4 | — | — | — |
Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.
Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.
Fuel economy and running cost
EPA ratings for each 2004 Chevrolet Cavalier version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Cavalier FWD | 2.2L 4-cyl | 5-speed manual | 23 | 33 | 27 | $2,500 |
| Cavalier FWD | 2.2L 4-cyl | 4-speed automatic | 21 | 31 | 25 | $2,700 |
| Cavalier Dual-fuel FWD | 2.2L 4-cyl · bifuel (cng) | 4-speed automatic | 21 | 29 | 24 | $2,800 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 04V300000Jun 23, 2004Seat belts › Rear/otherCovers: Chevrolet Cavalier 2004, Pontiac Sunfire 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.
Recall details for the 2004 Chevrolet Cavalier → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 409 on record; the latest 10 are shown.
- 11020816Jul 18, 2025Other or unknown. This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.
- 11017252Mar 28, 2025Electrical system, Other or unknown. This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.
- 11014455Feb 20, 2025Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get…
- 11009156Oct 25, 2024Electrical system. This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester…
- 11007744Sep 12, 2024Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical…
- 11007743Sep 12, 2024Other or unknown. This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical…
- 11007208Sep 6, 2024Other or unknown. 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…
- 11006621Aug 26, 2024Electrical system. 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…
- 11006421Jul 24, 2024Transmission and drivetrain. 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…
- 11004761Jun 28, 2024Fuel system, Engine. 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…
Other model years of the Chevrolet Cavalier
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2005 | 287 | 66,630 | 0 | — | 26 | Not compared (before 2008) | Stable |
| 2004 | 330 | 51,931 | 1 | — | 27 | Not compared (before 2008) | Falling |
| 2003 | 678 | 62,204 | 1 | — | 25 | Not compared (before 2008) | Falling |
| 2002 | 196 | 53,503 | 0 | — | 24 | Not compared (before 2008) | Stable |
| 2001 | 243 | 49,310 | 1 | — | 23 | Not compared (before 2008) | Stable |
| 2000 | 315 | 58,500 | 2 | — | 23 | Not compared (before 2008) | Rising |
| 1999 | 240 | 64,000 | 2 | — | 23 | Not compared (before 2008) | Stable |
| 1998 | 345 | 82,525 | 4 | — | 23 | Not compared (before 2008) | Stable |
| 1997 | 540 | 84,101 | 7 | — | 24 | Not compared (before 2008) | Stable |
| 1996 | 503 | 87,500 | 7 | — | 24 | Not compared (before 2008) | Stable |
| 1995 | 270 | 82,500 | 4 | — | 23 | Not compared (before 2008) | Stable |
| 1994 | 212 | 95,000 | 1 | — | 23 | Not compared (before 2008) | Stable |
| 1993 | 146 | 81,000 | 1 | — | 23 | Not compared (before 2008) | Stable |
| 1992 | 134 | 120,000 | 1 | — | 24 | Not compared (before 2008) | Stable |
| 1991 | 55 | 112,000 | 2 | — | 20 | Not compared (before 2008) | Stable |
| 1990 | 55 | 173,000 | 0 | — | 24 | Not compared (before 2008) | Stable |
| 1989 | 43 | 106,000 | 1 | — | 20 | Not compared (before 2008) | Stable |
| 1988 | 12 | 82,435 | 2 | — | 21 | — | Not enough data |
| 1987 | 24 | 86,394 | 2 | — | 24 | — | Stable |
| 1986 | 18 | 189,654 | 2 | — | 22 | — | Stable |
| 1984 | 8 | — | 2 | — | 25 | — | Not enough data |
All Chevrolet Cavalier model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2004 Chevrolet Cavalier?
Owners of the 2004 Chevrolet Cavalier most often describe instrument cluster problems: the speedometer, tachometer, fuel gauge and temperature gauge give wrong readings, stick, or quit entirely, frequently with well under 60,000 miles on the odometer. The issues reported most often: Speedometer and gauge cluster fail or read wrong; Stalls, no-starts or electrical cutouts linked to ignition; Power windows stop working or come off track.
How many NHTSA complaints does the 2004 Chevrolet Cavalier have?
NHTSA recorded 330 consumer complaints for the 2004 Chevrolet Cavalier as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Chevrolet Cavalier is reported most often?
Electrical system is named most often, in 185 complaints (56% of the total), followed by vehicle speed control with 27.
Has the 2004 Chevrolet Cavalier been recalled?
NHTSA lists 1 recall campaign for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 2004 Chevrolet Cavalier get?
The EPA rates the 2004 Chevrolet Cavalier (Cavalier, 2.2L 4-cyl) at 27 mpg combined, 23 city and 33 highway, with an estimated annual fuel cost of $2,500 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 2004 Chevrolet Cavalier reported?
Among the 262 complaints that include a mileage, the median is 51,931 miles and the middle half falls between 35,000 and 85,509 miles; 44% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.