2004 Chevrolet Cavalier

The 2004 Chevrolet Cavalier was a compact car offered in coupe and sedan body styles. It was known for its affordability and fuel efficiency, making it a popular choice for budget-conscious buyers. It was available with two engine options: a 2.2L Ecotec inline-4 producing 140 horsepower and 150 lb-ft of torque, and a less common 2.4L LD9 inline-4 making 150 horsepower and 155 lb-ft of torque. Both engines were available with either a 5-speed manual or a 4-speed automatic transmission. Owners generally appreciated the Cavalier’s simple design, ease of maintenance, and gas mileage. Common complaints included the car’s somewhat bland styling, cheap interior materials, and susceptibility to rust.

Engine

2.2L Ecotec L61

• Intake Manifold Gasket Failure
  • Description/Symptoms: Engine misfires, rough idle, and illuminated check engine light (often with codes P0171 or P0300). May also notice coolant loss.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $150 - $300
  • Recalls: None Found
• Crankshaft Position Sensor Failure
  • Description/Symptoms: Stalling, hard starting, or no start condition. Illuminated check engine light.
  • Solution: Replace the crankshaft position sensor.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

2.4L LD9

No Issues Found

Transmission

4T40E 4-Speed Automatic

• Slipping or Erratic Shifting
  • Description/Symptoms: Delayed or harsh shifts, transmission slipping between gears, or failure to shift at all.
  • Solution: In some cases, a fluid flush and filter change might resolve the issue. More severe cases may require a rebuild or replacement of the transmission.
  • Estimated Cost to Fix: $150 (fluid/filter) - $2000+ (rebuild/replace)
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering or vibrations, especially at low speeds or when accelerating. Stalling may occur.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found

5-Speed Manual

No Issues Found

Suspension

• Strut Mount Failure
  • Description/Symptoms: Clunking or rattling noises from the front suspension, especially when going over bumps. Poor handling and alignment issues.
  • Solution: Replace the strut mounts and potentially the struts themselves if they are worn.
  • Estimated Cost to Fix: $300 - $600 (per axle)
  • Recalls: None Found
• Sway Bar Link Failure
  • Description/Symptoms: Clunking or rattling noises, especially when turning or going over uneven surfaces. Reduced stability and handling.
  • Solution: Replace the sway bar links.
  • Estimated Cost to Fix: $100 - $200 (per pair)
  • Recalls: None Found

Electrical

• Power Window Regulator Failure
  • Description/Symptoms: Power windows that are slow, erratic, or fail to operate entirely. Clicking noises may be heard from the door.
  • Solution: Replace the power window regulator.
  • Estimated Cost to Fix: $200 - $400 (per window)
  • Recalls: None Found
• Ignition Switch Failure
  • Description/Symptoms: Intermittent starting problems, stalling, or complete failure to start.
  • Solution: Replace the ignition switch.
  • Estimated Cost to Fix: $150 - $300
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust developing on the rocker panels, door panels, fenders, and around the wheel wells.
  • Solution: Rust repair is a long process and will only delay further corrosion. Sand down the affected areas, apply rust converter, filler, primer, and paint. Replacing the panels will be costly.
  • Estimated Cost to Fix: $100 - $1,000+ depending on severity and repair method.
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The fabric headliner detaches from the backing and sags down.
  • Solution: Replace the headliner.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found
• Door Panel Fabric Detachment
  • Description/Symptoms: The fabric on the door panels begins to separate from the underlying panel.
  • Solution: Re-glue the fabric or replace the door panel.
  • Estimated Cost to Fix: $50 - $200 (reglue) / $100 - $300+ (replace panel, each)
  • Recalls: None Found

Summary

The 2004 Chevrolet Cavalier, while affordable and fuel-efficient, suffered from a range of common issues. Engine problems like intake manifold gasket and crankshaft position sensor failures can lead to drivability issues and moderate repair costs. Transmission problems, especially with the automatic, can be more severe and expensive to fix. Suspension issues and electrical problems can contribute to safety concerns and overall reliability. Rust is also a significant concern, especially in regions with harsh winters. Overall, while the Cavalier may be an inexpensive car to acquire, potential buyers should be aware of these common issues and factor in potential repair costs.