Brake Disc Rotor problems of the 2004 Chevrolet Malibu

Rotors repeatedly warp. Have had the brakes serviced twice within the 24000 warranty for brakes and it is requiring a third service at 26,000 miles outside of warranty. Rotors would need to be recut or replaced every 4,000 miles on this car to eliminate the pulsation. There is a systematic issue with the braking system, including the abs and/or the traction control. This is not a material or service issue, but a design issue. The dealer has indicated that all systems on the car are working properly and there is nothing they can do other than recut or replace the rotors. General motors has denied there is a problem which is expected possibly facing a recall of many cars. Although the dealer unofficially admitted this problem is a regular at their facility no one will officially admit this is an issue. Now that the brakes are outside of warranty at 26,000 miles, I am forced to pay for the service every 4,000 miles on my own. This could be a safety issue although the brakes have never failed to work. The affect of the design issue is that the brakes pulsate and progressively get worse as time goes on. Even after a few thousand miles the defect begins to surface. By 4,000 miles it is a big enough nuisance to have it serviced. This is an expense I had not bargained for when I bought this car.

2004 Chevrolet Malibu has rusted rotors. The dealer told the consumer the problem was normal.

Noticed front end shutter while applying brakes. Took car to dealer under warranty and extended warranty and dealer said excessive rust in brake pads. Also dealer said front rotors were warped. Dealer turned rotors and cleaned. Car had only 28k miles on it. Drove for a couple of days and problem came back. Took back to same dealer and he said rotors fine just excessive rust and brake dust. Nothing he could do. Car has 34k miles on it and in the rain, applied brakes and whole front end shuttered and anti- locks were grinding. Took back to dealer and they could find no problems. Now car has 42k miles and took to midas, they said front rotors severely warped and pads worn away. They could tell someone turned down rotors once and did bad job. Have to replace front rotors with different style rotors and new pads. Costs $500 dollars to replace. Chevrolet will not cover any of it even though existing problem.

Chevrolet Malibu model uses inferior brake rotors causing rotors to be warped almost immediately upon installation on vehicle. Upon taking delivery of 2004 Chevrolet Malibu in July 2004 it was immediately apparent that the front brake rotor was warped causing unsafe braking conditions and a general uneasyness when driving. Car was returned to dealer, and only offer on this brand new car was the resurface the rotors. This fix, while temporarily effective, to me is not acceptable on a new from the factory car. The same car has 18000 miles now, and the problem has again resurfaced. Upon further research online, this problem appears to be fairly widespread. I have not returned to the dealer to have it checked yet, but this is issue is not likely to be have been cause by poor driving habits by the user. I have another automobile that went over 50000 miles on it's original rotors and even at that point the rotors were not warped.

Rotors were replaced at 17,000 miles because they were warped. Then at 46,000 miles there was new pads put on the front of car,and rotors were machined at this time,as regular maintenance. Now at 60,000 miles the rotors need replaced again. There is a problem here and Chevrolet needs to realize it. Cars don't go through rotors every 20,000 miles. This gets expensive once the car is out of warranty. But chevy says its just how it is.

Consumer brake rotors began to warp after only 20000 miles. The consumer was told the rotors on the vehicle which were aluminum could not be properly resurfaced. The manufacturer discontinued the use of those particular rotors and the cost to replace them was 900. 00.