Which parts fail
Components named in complaints (front, side and curtain air bags, sensors and inflators).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Aveo owners, lightly cleaned up (personal details are redacted by NHTSA).
The vehicle was moving at a highway speed of approximately 65 MPH, when it got into a collision with another vehicle. The other vehicle made an abrupt stop on the highway in front of the 2004 Chevrolet Aveo, which caused the Aveo to hit the back of the suddenly stopped vehicle. Upon impact, the airbag did not deploy, which from my understanding should happen when traveling at that speed. In fact it especially should have deployed, due to the fact that the impact damaged the front of the vehicle. My concern is that I have bought two other vehicles from the same manufacturer since my purchase of this vehicle. I want to make sure that my family is safe when riding in these vehicles.
Takata recall. On October 13th 2018 I was in a horrific accident while on the highway was an single car accident my tire shredded but still maintained air and my airbags didn't deploy on either side and I got a broken nose and a few facial fractures. Now I have severe headaches everyday since then.
Tl* the contact owns a 2004 Chevrolet Aveo. The contact was driving 45 MPH when her vehicle was involved in a t-bone crash and the contact's vehicle crashed into the side of another vehicle. The air bags did not deploy. The contact suffered serious injuries and was transported to the hospital via ambulance. The vehicle was towed to insurance company lot but the vehicle was not examined to determine the cause of failure. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure and the current mileages were approximately 80,000. Updated 12/12/11
Tl contact owns a 2004 Chevrolet Aveo ls. While driving approximately 60 MPH, the contact crashed into a median and a snow bank. The air bags did not deploy. Approximately two months later, while driving approximately 65 MPH, the vehicle slid on black ice causing the vehicle to roll over and the air bags failed to deploy. The vehicle was destroyed. The contact did not mention if there were any injuries. A police report was filed. The dealer was notified and was unaware of the air bag failure. The current mileage was 85,000 and the failure mileages was 82,000.
While stopped at red light, our 2004 Chevy Aveo was struck from behind by a vehicle traveling about 25-45 MPH, which propelled the Aveo into the car in front of it. During the crash, the driver's seat moved backward into about a 45 degree angle and locked in that position and providing my daughter no protection against whiplash. She received injuries to her neck and abdomen, which would have been much worse if she had not been holding on tightly to the steering wheel. She was wearing her seat belt at the time of the crash, and the Aveo airbags did not deploy.
Tl contact owns a 2004 Chevrolet Aveo. While driving 25 MPH, another vehicle crashed into the contact's vehicle head on. The air bags failed to deploy. The fire department arrived and deactivated the air bag switch, so that the air bags would not deploy while removing her from the vehicle. The contact sustained major injuries by striking the steering wheel. The vehicle was destroyed and towed from the scene. The failure and current mileages were 66,322.
Car was traveling at approximately 40 km\h when a sudden stop occurred in traffic. My wife was about to change lanes and was looking in her blind spot and when she turned back she could not stop in time. She rear-ended another vehicle totaling her 2004 Aveo and then was hit from behind as well. The airbags did not deploy and due to this my wife has been in pain with her back and neck ever since. This occurred in ontario Canada.
Tl contact owned a 2004 Chevrolet Aveo. While driving approximately 35 MPH, the vehicle crashed into three deer. The air bags did not deploy. The vehicle was destroyed and the contact was injured. The contact was transported to the hospital and a police report was filed. The current and failure mileages were approximately 45,300.
Dt*: the contact stated while traveling 55 MPH the vehicle went in a ditch, causing damage to the front end. When this occurred the airbags did not deploy. The seat belt was worn, but the contact sustained minor injuries. The vehicle was towed to the contact's residence and has not been seen by a mechanic. Updated 05/03/06.
Tl* the contact owns a 2004 Chevrolet Aveo. The contact stated that the air bag warning indicator remained illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 140,390. Updated 09/22/16
Airbag complaints in other Aveo years
Frequently asked questions
How common are airbag problems on the 2004 Chevrolet Aveo?
NHTSA has 23 complaints about the air bags of the 2004 Chevrolet Aveo, 11% of the model year's 206 complaints. The component named most often is frontal (5 mentions).
Is there a recall for 2004 Chevrolet Aveo airbag problems?
No. NHTSA lists no air bags recall for the 2004 Chevrolet Aveo, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Chevrolet Aveo airbag problems start?
Half of the complaints with a recorded mileage happened before about 48,000 miles, and 26% before 25,000 miles.
Is it dangerous?
Owners linked 14 crashes, 0 fires and 13 injuries and 1 death to air bags problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.