Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chrysler PT Cruiser owners, lightly cleaned up (personal details are redacted by NHTSA).
My PT Cruiser by chrylr 2004 got on fire in the control areas for the gear control areas, I was driving home on the 29th of February 2016, and I was about a mile from my home when my grand daughter said she smell smoke and seen it as well, but we didn't know where it was coming from. I got home from driving a regular city street, which was about 5 minutes from my home. I park the car and raise the hood to see if the fire was under my hood, no not there. So I park my car at my home and said I would investigate it in the morning since it was night time. I went to my car the next morning on the 1st of March 2016 and try to change gears, my gear wouldn't move. I had my car tow to my mechanic to fix the problem. …
After shopping for 1/2 hour, I returned to my car in the parking lot. I opened the driver's side door and discovered gray colored smoke coming up from the steering column hazard button. It smelled odd. Not like wood smell. The auto club towed my car to my local mechanic and disconnected the battery connections as he said to prevent fire. My mechanic said the wires caught fire and melted the connectors. The parts: combination switch, combo switch connector & electrical connectors, shrink tubing = total $320 parts. Labor: remove & replace all applicable models (multi-function switch); replace multi-function switch harness (burned out connectors) = total $380 labor the day of the incident, I drove an estimated 15 miles total with two prior stops.
Tl* the contact owns a 2004 Chrysler PT Cruiser. While driving at 35 MPH, the left turn signal was activated and the contact noticed smoke coming from the left turn signal switch near the instrument panel. In addition, the contact stated that the fog lights remained illuminated and the contact had to lift the steering wheel upwards in order to engage the horn. The vehicle was not diagnosed or repaired. The failures recurred on numerous occasions. The manufacturer was not notified of the failures. The failure mileage was 30,000. The VIN was unavailable.
It started with the dashboard lights and the middle stick lights (p,d,r,n++) I can't see at night what speed I'm going or my levels or anything bc the lights quit working, I had the battery replaced I've had the battery changed twice, I've had the thermostat changed twice but it still over heats not too long ago with both of my toddlers in the car on a 3 lane highway locked up on me couldn't use the steering wheel or brakes had to pull the emergency break it's just been repetitive I bought the car from my sister who's grandmother got tired of putting money into it it stutters sometimes like it's slow to shift into gear to accelerate it can happen anywhere. It was my first car it's never been wrecked, I never thought to check for any recalls, I bought it in July of 17. It's only had a total of 2 owners. It used to shake real bad I couldn't go over 55miles an hour but even 55 was iffy. …
PT Cruiser on cruise control. Exit freeway and tap brake. Car begins to coast. As we approached stopped traffic the brake was applied again. Cruise kicked in again and instead of slowing we speeded up. Approximately 2:30 pm - no alcohol involved and no skid marks. Hit 5 other vehicles. My husband was driving and I was the passenger. I was very badly injured internally and had fractures to ribs, vertebra. And ankle. Seat belt and air bag saved my life but seat belt ripped my intestines and caused severe internal bleeding. My husband was in shock but without injury. It took 3 weeks to get a police report and on the report it stated that he had stepped on the accelerator instead of the brake. Not true -- not true. He yelled to me before the impact that the car was not stopping and I saw that he had the brake to the floor.
I was driving and the car caught on fire - electrical with flames inside the car. To the best of my knowledge the engine and body of the car were not damaged. The car is currently sitting on the dealer lot. It was reported to Chrysler and the car is under warranty; however, they are denying my claim. I wasn't hurt - just inhaled a lot of black smoke getting the car off the highway and into a parking lot. The windshield shattered from the heat as well as the entire dash to the left of the steering wheel is gone - and the plastic is melted and just hanging. Chrysler is refusing to do anything about my PT Cruiser even though it is under warranty. The 911 operator transferred me to the fire department - who have a report on the car.
The multifunction turn signal switch started to smoke and we couldn't turn off the fog lights. We had to pull the fuse since there continued to come smoke out of that switch -- we had to open the windows to drive home in order to get rid of the smell/smoke. Our Chrysler dealer said that this part is in high demand. The part was $275 and a similar high amount for labor the first time. From that time on I ordered online and replaced the switch two more times. Today, 10/01/2014, the switch started to smoke again. This would be the fourth switch. This is a known problem and should be a recall since it can cause a fire and drain the battery.
Tl contact owns a 2004 Chrysler PT Cruiser. While driving 35 MPH, the contact smelled an electrical burning smell coming from the instrument panel. Shortly afterwards, the instrument panel indicators stopped working. The contact then smelled burning plastic. The Chrysler dealer pulled the instrument cluster and discovered that the cluster circuit was burned. The dealer replaced the instrument cluster with a new part and they retained the old part. The failure mileage was 74,600.
Tl* the contact owns a 2004 Chrysler PT Cruiser. The contact replaced the multi-function electrical switch, which caused the fog lights to remain illuminated. The failure caused the battery to drain. The customer removed fuse #8 daily to reduce the possibility of an electrical fire. The contact had the multi-function switch replaced at henkel Chrysler Jeep Dodge (1275 w dickman rd, springfield, mi 49037, [phone]). The failure mileage was 108,773.
Fuel gauge suddenly drops to empty. Even after a complete tank refill. It would seem to be an electrical malfunction in either the sensor or dash gauge itself. It can be "cleared" from being stuck on empty by shutting off the engine and then restarting it. Also, speedometer suddenly drops to zero for several seconds and then jumps back to the present speed.
Electrical complaints in other PT Cruiser years
Frequently asked questions
How common are electrical problems on the 2004 Chrysler PT Cruiser?
NHTSA has 44 complaints about the electrical system of the 2004 Chrysler PT Cruiser, 20% of the model year's 217 complaints. The component named most often is wiring › interior/under dash (3 mentions).
Is there a recall for 2004 Chrysler PT Cruiser electrical problems?
No. NHTSA lists no electrical system recall for the 2004 Chrysler PT Cruiser, though it has 1 recall 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 Chrysler PT Cruiser electrical problems start?
Half of the complaints with a recorded mileage happened before about 76,000 miles, and 17% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 10 fires and 1 injury to electrical system 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.