2003 Pontiac Montana Problems

What owners report

Owners of this model year most often describe fuel leaks and fuel smells around the tank and filler neck, plus repeated brake-light bulb failures and moisture inside the headlight housings. Reports also include the van stalling with a total loss of power, air bags that failed to deploy in a crash, and engine cooling or gasket problems that appear from roughly 45,000 miles upward. Many complaints describe the dealer being unable to reproduce the problem or declining to cover the repair.

1. 1
   Exterior lighting

   Brake lights and headlights failing, moisture in lamps

   • 14 complaints (17%)
   • median 60,000 mi at 7.0 yrs old (13 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2004–2015

   Complaints describe brake-light bulbs burning out every few weeks, with melted plastic bulb bases and sockets that no longer make contact; some owners replaced the stop lamp switch without curing it. Others report water condensing inside the headlight housings, dimming the lamps and burning out bulbs, and say the whole housing had to be replaced. A few drilled drain holes or replaced housings repeatedly. Spread from about 15,000 to 150,000 miles, with several reports in the 50,000-90,000 mile range.

   3 related service bulletins

   What to check: Check both headlamp housings for condensation or water marks and pull the brake-light bulbs to look for melted or discolored bases. Ask whether the housings or sockets have already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “We have to kept changing the brake lights in the back because they keep going out ever few weeks. We even went and bought a new stop signal switch but that wasn't it. We want to know if there was a recall on the brake light and the wiring and why they keep going out. We have had issues since we bought in june 2014. We are just tired of keep pouring money into it but I don't want an accident or to get pull over either. The only light that never has an issue is the brake bar on top.”

   NHTSA complaint #10679563, filed 2015-01, 128,000 miles

   “We have owned the car since oct 2005, purchased used from a saturn dealership. Car was involved in a gas tank recall, however we were notified nearly two years after we had a rupture that dropped an entire tank of fuel on the driveway and were told we were lucky to be alive having driven unknowingly with this leak. Tank was replaced under extended auto warranty. Multiple electrical problems: tail light goes out and is replaced, then driver headlight goes out. Water leaks inside drivers side headlight when it rains. …”

   NHTSA complaint #10339878, filed 2010-06, 68,000 miles
2. 2
   Engine cooling

   Intake gasket leaks and coolant loss

   • 11 complaints (13%)
   • median 79,200 mi at 5.9 yrs old (10 state mileage)
   • filed 2005–2015

   Complaints describe coolant loss and, in some cases, an overheating engine traced to a failed intake manifold gasket; one owner reports a blown head gasket after the temperature gauge climbed quickly. Some say the repair was declined as out of warranty, and a few report repeat overheating after water pump, thermostat and coolant work. Separate complaints describe stripped rocker-arm bolts on the 3.4L engine requiring head replacement. Typically reported between about 30,000 and 130,000 miles, often in the 45,000-90,000 mile range.

   5 related service bulletins

   What to check: Check the coolant level and look for crusty residue at the intake manifold seams and around the water pump. Ask whether the intake gaskets have been replaced and whether the cooling system has been pressure-tested.

   2 excerpts from owner complaints in NHTSA records

   “This is my second Pontiac mini van with a leaking intake manifold gasket. The 1994 started leaking at 60k miles,my current van a 2003 is leaking at 45k miles. In my 94 van the engine failed at89k with religious oil changes and coolant flushes. My Montana also has had coolant and oil changes often. I know of others with the same problem.”

   NHTSA complaint #10156475, filed 2006-05, 45,499 miles

   “After heading home from taking my son to the er, my temp gauge started to rise fast to the red lines while I was going down the street. I quickly pulled over, put it in park and shut my engine off. I got out out of the car and looked under neath. Coolant was pouring all over the ground under the engine. Obviously couldn't drive so I had to call the husband to pick us up and a tow truck. Took the van to two different garages and they both said the head gasket blew. …”

   NHTSA complaint #10669519, filed 2015-01, 125,000 miles
3. 3
   Fuel system

   Fuel leak or gasoline smell at tank and filler neck

   • 14 complaints (17%)
   • median 78,200 mi at 6.2 yrs old (12 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2003–2016

   Owners describe a strong gasoline smell after filling the tank, fuel dripping or pooling under the rear of the van, and in some cases a visible crack at the tank seam near where the filler neck connects. Several say the tank or filler neck was replaced to stop the leak; some mention the van was outside the build range of a fuel-tank recall, or that they learned of the recall only after the leak occurred. Complaints also describe fuel vapors setting a warning light. Reported from very low mileage up to about 100,000 miles, most often right after refueling.

   Recall 07V349000

   What to check: Ask whether the fuel tank inlet check valve recall (07V349000) was performed and check the build date against the campaign. Look for staining or a fuel smell around the tank seam and filler neck after a fill-up.

   2 excerpts from owner complaints in NHTSA records

   “I filled my tank with gas and noticed the gas odor inside the vehicle immediately. Within the next two to three days the smell increased and I noticed it while walking around the vehicle outside. I took it for an oil change and they checked and found that there is a leak in the gas tank. There was no accident or injury preceding this leak.”

   NHTSA complaint #10255878, filed 2009-01, 88,400 miles

   “Wife detected a gas smell from the rear of her van. She let it go due to the recent fill up. I noticed a puddle under my wife's van and investigated the source of the puddle. I determined that the liquid was gas and it was streaming from around the inlet fuel valve and the fuel tank. I looked up the repair procedure on line and came across a recall for this issue on my particular van. (recall id# 07v349000) come to find out this recall was segregated to three mos. In 2002.(june-august) my particular date of assembly is oct. …”

   NHTSA complaint #10204709, filed 2007-10, 4,700 miles
4. 4
   Air bags

   Air bags fail to deploy, or deploy without a crash

   • 10 complaints (12%)
   • median 74,000 mi at 6.2 yrs old (6 state mileage, few)
   • 8 mention a crash, fire or injury
   • filed 2004–2022

   Several complaints describe front air bags not deploying in a collision, sometimes with the seat belt also reported as not holding the occupant. Others describe side or passenger air bags deploying with no impact, including while parked or while someone leaned across the seat, and one owner reports an air bag recall where the dealer had no part available. One complaint involves a previously repaired or salvaged van. Reported across a wide mileage range, from about 10,000 to 160,000 miles.

   Recall 03V051000Recall 02V222000

   What to check: Ask whether the driver-side air bag inflator recalls (03V051000, 02V222000) were completed and confirm the air bag warning lamp does the normal bulb check at start-up. Be wary of a van with a salvage or repaired-history title.

   2 excerpts from owner complaints in NHTSA records

   “I was in a accident and hit a truck broadside. I ended up hitting the steering wheel with my chest. Not only was my seatbelt ineffective, but the airbag did not open. I did sustain chest injury. Iran a stop sign in town.”

   NHTSA complaint #11150848, filed 2018-11

   “A 2003 Pontiac Montana was in a parking lot. People sitting in driver's seat and front passenger seat. The ignition was on but the car was still in park. Without any warning, both side air bags deployed, causing soft tissue injury to driver's left lower rib cage. There were no other cars involved; there was no contact with any other object.”

   NHTSA complaint #10361651, filed 2010-10, 152,000 miles
5. 5
   Electrical system

   Engine stalling and sudden loss of power

   • 9 complaints (11%)
   • median 15,649 mi at 1.5 yrs old (6 state mileage, few)
   • filed 2003–2008

   Owners describe the van cutting off without warning while driving, with steering and brakes losing assist and, in one case, the power door locks engaging so the driver had to exit through a sliding door. Some say the dealer could not find a fault; one report attributes a no-start to a faulty theft-deterrent module, another describes a fire that started under the hood while driving. Mostly reported under about 50,000 miles, including several under 15,000 miles.

   What to check: Ask whether any stalling or no-start diagnosis was done, including the theft-deterrent module, and check for stored fault codes. Have a shop look at battery cables and grounds, and note the condition of the ignition switch and key release.

   2 excerpts from owner complaints in NHTSA records

   “Montana keeps cutting off without a warning and it will stop dead in traffice with out a warning. This has happen a total of 7 times. The dealership keeps telling me that there is nothing wrong and that they can not find anything wrong with the 2003 Montana. I brought this Montana brand new last year 2003. There is a safty problem with this vehical. From vls..05/05/04.”

   NHTSA complaint #10068314, filed 2004-05, 14,898 miles

   “While driving my 2003 Montana stopped dead in traffice. The brakes lock and the steering wheel locked the vehical stopped dead with out any warning. It has stopped in traffic twice and a total of 7 time. Each time I took it back to the dealer they said that there was nothing wrong with the Montana. From vls 05/05/04.”

   NHTSA complaint #10068316, filed 2004-05, 14,898 miles

Buying note. Look closely at the fuel tank and filler neck for leaks or a fuel smell, confirm the open recalls for the fuel tank and driver-side air bag were completed, and check the headlights and brake lights for moisture and melted sockets. A pre-purchase inspection that includes a cooling-system pressure test and a scan for stored codes is worthwhile on a van of this age.

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.