2004 Pontiac Aztek Problems

What owners report

Owners of the 2004 Pontiac Aztek most often write in about fuel leaks and fuel smells, stalls and electrical shutdowns, and front wheel bearing noise. Fuel tank and filler neck leaks are reported across a wide mileage range, while wheel bearing and brake complaints tend to come in sooner. Several owners note that repairs for symptoms matching published fuel-system and ignition recalls were not covered for their vehicle.

1. 1
   Electrical system

   Engine stall and sudden loss of power

   • 19 complaints (28%)
   • median 9,900 mi at 1.5 yrs old (12 state mileage)
   • filed 2004–2018

   Owners describe the engine shutting off without warning at various speeds, sometimes at low speed in parking lots, sometimes on the highway, with steering and brake assist lost until the vehicle is restarted. A few report the ignition switch or key cylinder jamming so the key cannot be turned to the off position. According to complaints, dealers often could not reproduce the problem or found no stored codes, and in some cases replaced the computer or an ignition relay without a lasting fix. Reported at widely varying mileage, from a few thousand miles to well past 100,000.

   Recall 05V157000

   What to check: Ask whether the ignition relay recall work was performed, and test that the key turns freely to off and releases; have a mechanic check for stored codes if the car has ever cut out.

   2 excerpts from owner complaints in NHTSA records

   “Driving car on road and car quit running, electrical started flashing. Pulled over and ignition switch would only go to acc. Mode, it would not turn to off position. I had car towed to my house. The ignition will only go to acc. Mode will not turn to off position where key can be removed..unhooked battery terminal and car is still parked.”

   NHTSA complaint #10678243, filed 2015-01, 124,000 miles

   “While driving on the highway on vacation my aztec just shut off. I had it towed they reset the computer and sent it out the door. Eight hours later it did it again. I had it towed back and they found a bad ignition relay!! This thing is not even four months old.”

   NHTSA complaint #10074801, filed 2004-06, 2,690 miles
2. 2
   Fuel system

   Fuel tank and filler neck leaks / gas smell

   • 17 complaints (25%)
   • median 98,126 mi at 8.3 yrs old (13 state mileage)
   • filed 2004–2020

   Complaints describe a strong gasoline smell while driving or after parking, and in some cases fuel dripping or pooling on the ground, often traced to the seam or weld of the fuel tank, the inlet check valve, or the filler neck. Owners frequently say they later learned of a fuel-system recall but were told their vehicle's identification number was not included and that the repair would be at their own cost. Repairs reported include replacing the whole fuel tank and seal. Appears from low mileage up past 100,000 miles, but is reported most often on vehicles with roughly 37,000 to 104,000 miles.

   Recall 07V349000Recall 03V454000

   What to check: Smell around the rear of the vehicle and look for staining or drips under the tank after it has sat; ask whether any fuel-tank recall work was ever completed on this specific vehicle.

   2 excerpts from owner complaints in NHTSA records

   “The weld between the fuel tank inlet check valve and the fuel tank has failed causing a gas leak. There was an earlier recall issued (NHTSA recall no. 03v454/GM recall no. 03055) that was limited to 79 vehicles. I own a 2004 model that is not one of the 79 vehicles and I am encountering the exact same problem as what is outlined in the recall. I believe more vehicles are affected that what is noted by GM.”

   NHTSA complaint #10164180, filed 2006-08, 37,589 miles

   “My 2004 Pontiac aztec rally edition has a leak in the fuel tank. The dealership is telling me that it is not on recall. I see recalls on the system. Need to know why my model has not been recall.”

   NHTSA complaint #10462530, filed 2012-06, 160,000 miles
3. 3
   Brakes

   ABS light, grinding brakes and weak stopping

   • 10 complaints (15%)
   • median 44,304 mi at 6.7 yrs old (7 state mileage, few)
   • filed 2004–2019

   Owners report the antilock brake warning light coming on along with grinding, crunching or pulsing from the brakes, sometimes with the pedal going to the floor and brake fluid leaking from fractured hoses. Several say pads, rotors, calipers or hubs were replaced but the warning light and noise returned. Some complaints link the symptoms to a wheel speed sensor, hub assembly or control module. Mostly reported from very low mileage up to about 57,000 miles, with a few beyond 100,000.

   What to check: Confirm the ABS light comes on and then goes out after start-up, check brake fluid level and look for wet spots at the hoses, and ask for service records on brake and hub work.

   2 excerpts from owner complaints in NHTSA records

   “Dt: the brakes were replaced 6 times. The brakes continuously squeal and crunch. The dealership continues to replace items one at a time. They have not stated what the problem was. The manufacturer requested that the consumer return to the dealer. The problem started approximately april 15, 2005. The vehicle was purchased new.”

   NHTSA complaint #10128582, filed 2005-07, 11,000 miles

   “Abs system lights went on and ABS system exhibits crunching, grinding, noisy and abnormal pulsing operation. June 2012 message indicates rf hub needs replacement. Done. Abs system acts up again in under 30 days same symptoms. Rear brakes/drum replaced 6/2013, ABS problems still present. Front brakes replaced 8/2013, ABS problems still present. 8/2013 taken to GM dealer service for analysis. Speed sensor replaced, ABS problem still present. Dealer advises that lf hub needs replacing and ABS harnesses on both sides. …”

   NHTSA complaint #10619291, filed 2014-08, 129,219 miles
4. 4
   Suspension

   Front wheel bearing noise and repeat replacement

   • 9 complaints (13%)
   • median 55,588 mi at 3.4 yrs old (8 state mileage, few)
   • filed 2006–2009

   Complaints describe a loud grinding or humming noise and vibration from the front of the vehicle, diagnosed as a worn front wheel bearing or hub assembly. Several owners report both front bearings replaced within a short span, and some had a bearing fail again months after replacement. One owner was told only certain bearing serial numbers were covered by an internal notice. Typically reported between about 46,000 and 70,000 miles, with some as low as 48,000.

   What to check: Listen for humming or grinding that changes with vehicle speed and while turning; ask which bearings and hubs have already been replaced and when.

   2 excerpts from owner complaints in NHTSA records

   “Both front wheel bearings had be replaced at 62000. I am now having to replace the passenger side again 7 1/2 months later. The dealer told me there was a select few serial numbers on the wheel bearings that they were being replaced under a safety alert but mine was not one of them.. So even though I was having the same problem I am having to pay for mine twice.”

   NHTSA complaint #10205208, filed 2007-10, 67,000 miles

   “On april 17, 2006, I brought my 2004 Aztek in to the Pontiac dealer because there was a loud grinding noise and vibration coming from under the front passenger side of my vehicle. I was told that the front right wheel bearing was failing, and that it had to be replaced. Since it was just out of warranty, at 63,031 miles, I paid for this repair. Then, on september 13, 2006, I heard the same noise and vibration coming from the front drivers side of my vehicle. …”

   NHTSA complaint #10173458, filed 2006-11, 63,031 miles

Buying note. Given the age of this model year, service records matter more than anything else: ask specifically about fuel tank and ignition relay recall completion, and have any candidate vehicle inspected for fuel leaks, wheel bearing noise and ABS faults before purchase.

Summary written with AI from a sample of 59 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.