2004 Nissan Armada Problems

What owners report

Owners of the 2004 Armada report two dominant themes in this sample: brake problems and, at higher mileages, rusted structural and suspension parts. The most common brake complaint is a sudden loss of braking power accompanied by a brake warning light, a grinding or spring-like noise, and a fix that only lasts until the vehicle is shut off and restarted. Rotor shudder and premature brake wear also appear, often at very low mileage.

1. 1
   Brakes

   Sudden loss of braking with warning light, resets on restart

   • 249 complaints (54%)
   • median 69,529 mi at 7.5 yrs old (206 state mileage)
   • 12 mention a crash, fire or injury
   • owner-quoted repair $1,000 (median of 12 quotes)
   • filed 2004–2026

   Owners describe the brake warning light coming on while driving, followed by a long, soft pedal and a grinding or spring-like noise, with braking reduced to a small fraction of normal. Several say the condition clears after shutting the engine off and restarting, then returns later. Complaints mention dealers either finding nothing wrong, resurfacing or replacing pads and rotors, or pointing to the brake booster or an ABS/VDC software update. Reported across a wide mileage range, from a few thousand miles to well past 100,000, at city and highway speeds alike.

   3 related service bulletins

   What to check: Ask whether the ABS/VDC module has been inspected or reflashed, and whether the brake booster has been checked. During a test drive, note any brake warning light, grinding noise, or pedal that sinks toward the floor.

   2 excerpts from owner complaints in NHTSA records

   “2004 Nissan Armada - brake failure. This is an on-going problem. I have contacted Nissan in the past to open a claim. The person on the phone recommended I take it to the dealer (which we had done at least 3 times prior). We took it to the dealer and they indicated that there was 'no trouble/problem found' (only one time prior did they update the code to the computer - all other times - no trouble found). …”

   NHTSA complaint #10273645, filed 2009-06, 68,000 miles

   “I have an 04 Armada we were driving it a week ago, when we came to a stop sign and the brakes failed. It made a grinding noise, brake lights were on but no brakes very scary for us. This has happened numerous times and Nissan told me its the brake booster that's failing but it is not under warranty and therefore not covered. Researching this there is hundreds if not thousands of the same brake issue with these armadas.”

   NHTSA complaint #10467790, filed 2012-07, 100,000 miles
2. 2
   Brakes

   Brake shudder and rotor warping

   • 151 complaints (33%)
   • median 13,000 mi at 1.8 yrs old (122 state mileage)
   • 6 mention a crash, fire or injury
   • filed 2004–2021

   Owners report steering wheel shake and vibration when braking, sometimes with a pulsing pedal, appearing at low mileage and returning within a few thousand miles after the dealer turned or replaced the rotors. Several complaints say the fix was repeated resurfacing rather than a lasting repair, and some note rapid pad wear or a pull to one side when stopping. Often reported under 20,000 miles, with recurrence a few thousand miles after each repair.

   2 related service bulletins

   What to check: Test-brake from highway speed and feel for steering wheel shake or pedal pulsation. Ask for service records showing whether rotors were resurfaced or replaced and how recently.

   2 excerpts from owner complaints in NHTSA records

   “I have brought my Nissan armanda 2004 4x4 le in several times after researching several web-sites the brakes, rotors and ABS sensors are a constant issue with this model. To this date my dealer can not fix this issue. I am concerned about the safety of my family and others on the road. This brake issues occurs while driving with no notification until you try to stop.”

   NHTSA complaint #10236464, filed 2008-07, 13,000 miles

   “My 2004 Nissan Armada brakes failed at 24,500 miles. They were replaced by the dealer under a tb due to shaking and premature wear at 16,000 miles. The brake lights suddenly came on and brakes started to shake making me lose control. Checked brake and they were down to metal at less then 10,000 miles.”

   NHTSA complaint #10284640, filed 2009-09, 24,500 miles
3. 3
   Engine cooling

   Cracked exhaust manifolds and exhaust smell in cabin

   • 19 complaints (4%)
   • median 80,000 mi at 7.7 yrs old (17 state mileage)
   • filed 2004–2021

   Complaints describe an abnormal exhaust sound and exhaust fumes entering the cabin, with the dealer diagnosing cracked exhaust manifolds needing replacement. Some owners say the manifolds were replaced and later cracked again, and others report the work was declined because the vehicle was outside the warranty period. Mostly reported between roughly 40,000 and 90,000 miles.

   What to check: Listen for a ticking or hissing exhaust note near the engine bay at cold start, and check for exhaust smell inside the cabin with the blower on. Ask for records of any manifold replacement.

   2 excerpts from owner complaints in NHTSA records

   “My problem started around 12/5/08 when my truck died unexpectedly. It restarted then later more of the same on the same voyage. Local Nissan was contacted that day and an appointment was set for 12/15/08. At that appointment it was determined that it was caused by the vehicle security function and was reset and key was reprogrammed. They had noted that the exhaust manifolds had failed and needed replacement. The mileage was 81,470, 1470 miles over the federal warranty. …”

   NHTSA complaint #10256419, filed 2009-01, 81,470 miles

   “Cracked exhaust manifold identified. Dealer took 2 months after requesting a trip to the dealership (200 miles rt) to deny any responsibility because vehicle is over 8 years new. Been cracked for years and they knew its age before requesting an inspection. We were told by dealership to be wary of exhaust leaking into the cabin.”

   NHTSA complaint #10621210, filed 2014-08, 67,000 miles
4. 4
   Electrical system

   Engine stalls or will not start (electrical / IPDM relay)

   • 28 complaints (6%)
   • median 125,000 mi at 8.5 yrs old (22 state mileage)
   • filed 2004–2021

   Complaints describe the engine cutting out while driving, sometimes with rapidly flashing dashboard lights, and difficulty restarting. Other owners report the vehicle failing to start with the battery gauge swinging and control systems behaving erratically; some were told the security/key function needed a reset or reprogramming. Reported from a few thousand miles up to roughly 90,000, in varied driving conditions.

   Recall 10V5170003 related service bulletins

   What to check: Ask whether the IPDM/ECM relay recall (10V517000) was completed, and check service history for battery, key, and starting-system repairs.

   2 excerpts from owner complaints in NHTSA records

   “While driving about 45 MPH in the night time, suddenly dash board lights flashes very rapidly and stalls the engine. Luckily, no other car was next to us. We safely stopped the our 2004 Nissan Armada SUV on the side of road. After about 10~15 minutes, we tried to re-start the car, but no luck. After giving gas pedal several times, we could re-start the car. We drove home (about 5 miles in distance) safely. …”

   NHTSA complaint #10326640, filed 2010-04, 70,037 miles

   “In november 2004 I purchased the Armada 2004. I drove it to florida in december 2004 and left it in my house. I left with the military until june 2005, I drove the vehicle several times until july 2005, in which, one morning I try to turn it on, the vehicle did not start and it sounded like the battery or starter was not working properly. The battery gage went from half way to the negative side and then back to the middle and once again to the negative side again. The control systems are still showing negative information of being off or on. …”

   NHTSA complaint #10131493, filed 2005-08, 1,820 miles
5. 5
   Body and structure

   Rusted subframe and underbody structure

   Mentioned in 4 of 60 sampled complaints

   Owners describe severe corrosion of the rear subframe, control arms, and sway bar mounts, sometimes found only when the vehicle is on a lift for alignment or inspection. Complaints say the sway bar had rusted through and that welding holding suspension parts appeared weakened; on some vehicles the condition was confirmed by a dealer but not repaired. Typically found between roughly 70,000 and 200,000 miles, often on vehicles from colder, road-salt regions.

   What to check: Have the vehicle inspected on a lift before purchase, specifically the rear subframe, control arms, and sway bar mounts. Ask where the vehicle was previously registered, since road-salt exposure matters.

   2 excerpts from owner complaints in NHTSA records

   “We have a 2004 Nissan pathfinder Armada with under 74,000 miles on the odometer. The vehicle looks like it is in very good shape until it is put on a lift. The major control arms of the vehicle are severely rusted while other steel in close proximity is not. We found a recall for 1996-2004 Nissan pathfinders for this same issue: 'campaign id #: r1107 'NHTSA #:11v-244 'applied vehicles:1996-2004 pathfinder (r50) Nissan north american told us that this recall does not apply to our vehicle. …”

   NHTSA complaint #10972193, filed 2017-04, 74,000 miles

   “After purchasing a 2004 Nissan Armada. Took to get a alignment and he mechanic diagnosed the rear subframe/cradle was severely rusted nearly in two so much so that the sway bar had rusted through completely and was just hanging loosely. After doing some research we have seen multiple reports of this recurring issue.”

   NHTSA complaint #11323456, filed 2020-05, 346,881 miles

Buying note. The brake complaints are the most frequent and the most consequential, so a thorough braking test and a look at service records are worth prioritizing. On an older, high-mileage example, also have the underbody and exhaust manifolds inspected 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.