The 2004 Rendezvous is a FWD/AWD crossover sharing GM's 3400/3500 V6 platform with notorious intake manifold gasket issues and a 4T65-E transmission prone to cooler line leaks and internal wear. These two systems dominate the failure profile.
Intake Manifold Gasket Failure (3.4L V6)
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: External coolant leaks at front/rear of engine, White smoke from exhaust on cold start, Coolant loss with no visible external puddle, Rough idle or misfire from coolant entering cylinders
Fix: Replace upper and lower intake gaskets, typically 6-8 hours labor. Often discover warped intake plenum requiring machining or replacement. Smart techs do coolant elbows and thermostat housing at same time since they're plastic and accessible. Dexcool system must be flushed.
Estimated cost: $800-1,400
Transmission Oil Cooler Line Leaks
Common · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Transmission fluid dripping near radiator, Pink fluid on ground under front of vehicle, Burned transmission smell, Slipping gears or delayed engagement from low fluid
Fix: Steel cooler lines rust through where they connect to radiator or transmission. Quick-fix is splice-in rubber hose section (1 hour), but proper repair replaces entire hard line assemblies (2-3 hours). Buried behind subframe and A/C lines. Always check for internal transmission damage if ran low on fluid.
Estimated cost: $300-700
4T65-E Transmission Failure
Common · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Harsh 1-2 or 2-3 shifts, Slipping under load especially in 2nd gear, Shuddering during light acceleration, No reverse or delayed reverse engagement
Fix: Input shaft splines wear, 2nd gear clutches burn, and pressure control solenoid issues plague this transmission. Rebuild runs 12-16 hours, remans available but quality varies. Many owners opt for used units given vehicle value. Fluid changes every 50k help but don't prevent inevitable wear.
Estimated cost: $2,200-3,800
Lower Engine Failure (3.4L)
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: Loud knocking from bottom of engine, Metal shavings in oil, Sudden loss of oil pressure, Catastrophic failure after overheating event
Fix: Connecting rod bearings fail from Dexcool sludging and inadequate oil change intervals. Repair requires complete lower-end rebuild or replacement (20-25 hours). Usually not economical given vehicle value. Caused by combination of intake gasket leaks allowing coolant contamination and extended oil change intervals.
Estimated cost: $3,500-5,500
Power Window Regulator Failure
Common · low severity
Typical onset: 70,000-120,000 mi
Symptoms: Window drops into door with loud pop, Window moves slowly or won't go up, Grinding noise when operating window, Window sits crooked in door frame
Fix: Plastic window regulators crack and cables fray. Driver side fails first, then passenger. Requires door panel removal and regulator replacement (1.5-2 hours per door). Aftermarket regulators acceptable but get ones with metal brackets.
Estimated cost: $250-400
AWD Transfer Case Fluid Leak
Occasional · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Gear oil dripping from center of vehicle, Grinding or whining from transfer case on turns, AWD warning light illuminated, Binding sensation during tight turns
Fix: Output shaft seals leak on AWD models. Requires transmission removal to access (8-10 hours) or drop subframe for seal replacement. Many techs just top off fluid until it becomes catastrophic. Full replacement of transfer case if bearings damaged from running dry.
Estimated cost: $600-1,200
EVAP Fuel Tank Pressure Sensor Failure
Common · low severity
Typical onset: 80,000-150,000 mi
Symptoms: Check engine light with P0440, P0442, P0446 codes, Fuel smell near tank, Difficulty filling fuel tank (pump clicks off early), Hissing sound when opening fuel cap
Fix: Pressure sensor on top of fuel tank fails, and vent valves stick. Related to recall but many still have issues. Tank must be dropped (2-3 hours). Common to find rusted fuel tank straps and filler neck on rust-belt vehicles, adding cost.
Estimated cost: $350-650
Owner tips
Change Dexcool coolant every 3 years regardless of mileage—extended-life claims don't apply after gasket leaks start
Transmission fluid exchange every 50,000 miles mandatory; 4T65-E doesn't tolerate neglect
Inspect transmission cooler lines annually on rust-belt vehicles; catch leaks before transmission damage
Budget $1,500/year for deferred maintenance on any example over 100k miles
Buy only if under $3,000 with recent transmission service and confirmed intake gaskets done; otherwise you're financing someone else's deferred maintenance on a platform with two inevitable expensive failures.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: Side post terminals; standard engine bay location
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Every control module on the 2002-2007 Buick Rendezvous — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
Electronic Brake Control Module (EBCM)1.8 hr R&Rrelearn only +0.3 hr▸ programming details
📍 Engine compartment, driver side inner fender area, mounted to ABS hydraulic unit
🔧 GM Tech 2
⚠️ Brake bleeding and automated bleed procedure required after replacement; no VIN programming needed
Body Control Module (BCM)1.5 hr R&Rdealer / factory tool +1.0 hr▸ programming details
📍 Behind center console, below radio/HVAC assembly, accessible from passenger side
🔧 GM Tech 2 with TIS2000/SPS
⚠️ VIN programming required; controls PassLock II theft deterrent; must perform 10-minute relearn after programming
📍 Under driver seat, mounted to seat frame (when equipped)
🔧 Manual reprogramming
⚠️ Optional on CXL models; memory positions must be manually reset by driver after replacement
Transmission Control Module (TCM)no coding
📍 Integrated within PCM (4T65-E transmission)
⚠️ TCM function integrated into PCM; no separate module
Theft Deterrent Module (TDM)no coding
📍 Function integrated within BCM
⚠️ PassLock II system integrated into BCM; no separate module
Electronic Power Steering Control Module (PSMC)no coding
📍 Not equipped - hydraulic power steering only
⚠️ Rendezvous uses conventional hydraulic power steering; no electronic module
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
ON CERTAIN VEHICLES, VARIATIONS IN THE MANUFACTURING PROCESS OR EXPOSURE TO HIGH AMBIENT TEMPERATURES MAY LEAD TO FRACTURE OF THE FUEL TANK INLET CHECK VALVE (ICV).
Consequence: A FRACTURE MAY ALLOW FUEL VAPORS TO PASS THROUGH AND ALLOW DROPLETS OF FUEL TO ACCUMULATE ON THE SIDE OF THE FUEL TANK. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL TANK. THE RECALL WILL BE MAILED IN TWO PHASES WITH THE FIRST PHASE BEGINNING ON DECEMBER 4, 2007. THE SECOND PHASE WILL BE MAILED ON DECEMBER 13, 2007. OWNERS MAY CONTACT BUICK AT 1-866-608-8080; CHEVROLET AT 1-800-630-2438; OR PONTIAC AT 1-800-620-7668. THE VEHICLE POPULATION INCLUDES BUICK RENDEZVOUS AND PONTIAC AZTEK VEHICLE BUILT IN MAY 2003; CHEVROLET VENTURE AND PONTIAC MONTANA VEHICLES BUILT FROM JUNE THROUGH AUGUST 2002; AND ALL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO, AND HAWAII.
CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.
Consequence: FUEL MAY LEAK, POSSIBLY RESULTING IN A FIRE.
Remedy: DELPHI WILL NOTIFY OWNERS AND REPLACE THE UPR FREE OF CHARGE. THE RECALL BEGAN ON APRIL 23, 2007. OWNERS CAN CONTACT DELPHI AT 877-411-8770.
ELECTRICAL SYSTEM:IGNITION · 05V157000
2005-04-20
ON CERTAIN SPORT UTILITY VEHICLES, CONTAMINATION ON IGNITION RELAY CONTACTS CAN CAUSE HIGH RESISTANCE. THIS CAN AFFECT SIGNALS TO THE POWERTRAIN CONTROL MODULE AND, COULD CAUSE INTERMITTENT VEHICLE STALLS AT ANY TIME.
Consequence: THE VEHICLE CANNOT BE RESTARTED IMMEDIATELY. IF THIS WERE TO OCCUR, IT COULD RESULT IN A VEHICLE CRASH.
Remedy: DEALERS WILL REPLACE THE IGNITION RELAY FREE OF CHARGE. THE RECALL BEGAN ON MAY 4, 2005. OWNERS MAY CONTACT PONTIAC AT 1-800-620-7668 AND BUICK AT 1-866-608-8080.
ON CERTAIN SPORT UTILITY VEHICLES, A STRUCTURAL SUPPORT AT THE LATCH ATTACHMENT IN THE REAR LIFTGATE MAY BE INADEQUATE TO RETAIN THE LATCH TO THE LIFTGATE IN CERTAIN SEVERE VEHICLE CRASH EVENTS.
Consequence: IF THE LIFTGATE WERE TO OPEN IN A VEHICLE CRASH, AN OCCUPANT COULD BE EJECTED FROM THE VEHICLE RESULTING IN INCREASED RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL ADD STRUCTURAL REINFORCEMENTS TO THE LIFTGATE IN THE AREA ADJOINING THE LATCH ASSEMBLY. OWNER NOTIFICATION SCHEDULE BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT BUICK AT 1-866-608-8080. THIS IS AN EXPANSION TO A PREVIOUS RECALL (03V211).
FUEL SYSTEM, GASOLINE:STORAGE · 03V454000
2003-11-10
ON CERTAIN PASSENGER VEHICLES, A WELD BETWEEN THE FUEL TANK INLET CHECK VALVE AND THE FUEL TANK CAN FAIL.
Consequence: IF THESE PARTS SEPARATE, THE DRIVER MAY NOTICE AN ODOR OF FUEL, THE SERVICE ENGINE SOON OR CHECK ENGINE LIGHT MAY ILLUMINATE, AND/OR FUEL MAY LEAK ONTO THE GROUND. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT THE SERIAL NUMBER OF THE FUEL TANK TO SEE IF IT IS ON THE LIST OF AFFECTED TANKS. IF THE SERIAL NUMBER MATCHES, THE FUEL TANK WILL BE REPLACED. OWNER NOTIFICATION BEGAN NOVEMBER 4, 2003. OWNERS SHOULD CONTACT BUICK AT 1-866-608-8080 OR PONTIAC AT 1-800-620-7668.
Wiper blades
Crossover SUV with rear wiper. Both front wipers are the same length.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2004 Buick Rendezvous 3.6L V6 and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.