The 2004 Impala SS with the supercharged 3.8L Series II is a solid performer, but the L67 engine has known bottom-end weaknesses and the 4T65E-HD transmission has cooling and mount issues that need attention.
Lower Intake Manifold Gasket Failure
Common · medium severity
Typical onset: 80,000-120,000 mi
Symptoms: Coolant leaks at front of engine, Overheating, White smoke from exhaust on cold start, Coolant loss with no visible external leak, Rough idle when cold
Fix: Replace lower intake manifold gaskets (Fel-Pro 1200 kit preferred). Requires removing supercharger, fuel rails, and upper plenum. 6-8 hours labor. Also replace thermostat and coolant elbows while you're in there.
Estimated cost: $800-1,400
Connecting Rod Bearing Failure
Occasional · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Loud knocking on cold start that quiets with oil pressure, Metallic rapping that increases with RPM, Low oil pressure warning, Metal shavings in oil during changes, Sudden catastrophic failure with no warning in some cases
Fix: L67 Series II engines have undersized rod bearings from factory. Once knocking starts, you need crank polishing, new bearings, and rod inspection minimum (8-12 hours). Often progresses to full rebuild with pistons and rings when machine work is needed. Many opt for 0.001" oversize bearings as preventive measure.
Estimated cost: $2,500-5,500
Transmission Oil Cooler Line Failure
Common · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Transmission fluid leaking near radiator, Pink fluid dripping under front of car, Transmission slipping or delayed engagement, Milky appearance in transmission fluid (coolant contamination), Overheating transmission
Fix: Steel lines corrode where they attach to radiator. Replace both cooler lines and external filter. If coolant mixed with ATF, flush cooler and possibly rebuild transmission. Lines alone: 2-3 hours. With transmission damage: add 12-18 hours for rebuild.
Symptoms: Clunking when shifting from Park to Drive/Reverse, Vibration at idle in gear, Visible engine movement when accelerating, Transmission jerking on hard acceleration
Fix: Rear transmission mount deteriorates from heat and torque stress. Replace transmission mount and inspect torque strut mounts. 1.5-2 hours labor. Use OEM or upgraded polyurethane mount.
Estimated cost: $200-350
Supercharger Coupler Failure
Occasional · medium severity
Typical onset: 90,000-130,000 mi
Symptoms: Whining or squealing from supercharger, Loss of boost and power, Check engine light with MAF/fuel trim codes, Rubber debris in intake, Supercharger spinning freely without resistance
Fix: Rubber coupler between supercharger snout and input shaft deteriorates. Replace coupler and inspect snout bearing. 4-5 hours labor. While apart, check snout bearing play and consider rebuild if loose.
Symptoms: External coolant leaks at head/block junction, Overheating, Rough running and misfire, Exhaust gases in coolant reservoir, Rapid coolant loss
Fix: Gaskets fail from age and repeated heat cycles. Requires removing supercharger, fuel system, and both heads. Resurface heads, new bolts required. 12-16 hours labor. Often combined with lower intake gaskets if not already done.
Estimated cost: $2,200-3,800
Fuel Pump and Pressure Regulator Issues
Occasional · medium severity
Typical onset: 100,000-150,000 mi
Symptoms: Hard starting, especially when hot, Loss of power under boost, Fuel smell from engine bay, Check engine light with fuel trim codes, Stalling at idle or during acceleration
Fix: In-tank pump wears or pressure regulator on fuel rail leaks. Tank drop for pump: 3-4 hours. Regulator replacement: 2 hours. Always replace fuel filter during pump work (external frame-mount canister).
Change transmission fluid every 50,000 miles with Dexron VI — the 4T65E-HD runs hot with the supercharged engine
Use 0.001" oversize rod bearings preventively if you're doing any bottom-end work — factory bearings are marginal
Replace lower intake gaskets BEFORE they fail to avoid coolant damage to bearings and cylinders
Run quality synthetic oil (5W-30) and change every 3,500-4,000 miles — supercharged engines are hard on oil
Inspect transmission cooler lines annually after 80,000 miles — catching corrosion early prevents transmission contamination
Buy one if the lower intake and transmission cooler lines have already been done and oil analysis shows clean bearings — skip it if there's any bottom-end noise or unknown maintenance history.
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.
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General Motors LLC (GM) is recalling certain model year 1998-1999 Chevrolet Lumina and Oldsmobile Intrigue, 1997-2004 Buick Regal and Pontiac Grand Prix, 2000-2004 Chevrolet Impala, and 1998-2004 Chevrolet Monte Carlo vehicles. The affected vehicles were previously repaired under recalls 08V-118, 09V-116, and 15V-201 to address the possibility that engine oil may drip onto the hot exhaust manifold.
Consequence: Engine oil that drips onto the hot surface of the exhaust manifold may result in a fire.
Remedy: The remedy applied under recalls 08V-118, 09V-116, and 15V-201 did not adequately remove the safety risk. Under the improved remedy, dealers will replace the engines front valve cover and gasket. Vehicles that are covered by recalls 08V-118, 09V-116, or 15V-201 that have not yet received the original remedy will instead receive the improved remedy under the original recall number. The recall began on February 19, 2016. Owners may contact Chevrolet customer service at 1-800-222-1020, Buick customer service at 1-800-521-7300, Oldsmobile customer service at 1-800-442-6537 and Pontiac customer service at 1-800-458-8006. GM's number for this recall is 15757. Note: Until the improved remedy has been applied, owners are advised to park their vehicle outside since the fire risk exists even when the vehicle is unattended.
ENGINE AND ENGINE COOLING:ENGINE · 15V201000
2015-04-06
General Motors LLC (GM) notified the agency on April 2, 2015, that they are is recalling certain model year 2004 Buick Regal vehicles manufactured April 9, 2003, to June 1, 2003, 2004 Chevrolet Impala vehicles manufactured April 8, 2003, to June 23, 2003, and 2004 Chevrolet Monte Carlo vehicles manufactured April 7, 2003, to June 23, 2003. On May 18, 2015, GM expanded the recall to cover an additional 49,751 2004 Pontiac Grand Prix vehicles manufactured January 6, 2003, to June 25, 2004. In the affected vehicles, the valve cover gasket may leak.
Consequence: The leaking engine oil can drip onto the hot surface of the exhaust manifold, increasing the risk of a fire.
Remedy: GM will notify owners, and dealers will remove the plastic cover and plastic oil fill tube extension and replace the front valve cover and gasket. These repairs will be done free of charge. The recall began on April 24, 2015. Owners may contact Buick customer service at 1-800-521-7300, Pontiac customer service at 1-800-762-2737 or Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 14574.
ELECTRICAL SYSTEM:IGNITION · 14V400000
2014-07-03
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring.
General Motors LLC (GM) notified the agency on July 3, 2014, that they are recalling 5,877,718 model year 2000-2005 Chevrolet Impala and Monte Carlo, 1997-2003 Chevrolet Malibu, 2004-2005 Malibu Classic, 1999-2004 Oldsmobile Alero, 1998-2002 Oldsmobile Intrigue, 1999-2005 Pontiac Grand Am and 2004-2008 Pontiac Grand Prix vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will install two key rings and an insert in the key slot or a cover over the key head on all ignition keys, free of charge. The recall began on September 9, 2014. GM's number for this recall is 14350.
STEERING · 09E005000
2009-02-17
DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.
Consequence: A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARNING.
Remedy: DORMAN WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE STEERING KNUCKLES FREE OF CHARGE AND REIMBURSE THE REPAIR FACILITY OR OWNER FOR LABOR. THE RECALL BEGAN ON FEBRUARY 23, 2009. OWNERS MAY CONTACT DORMAN'S TOLL-FREE HOTLINE AT 1-800-523-2492 AND PRESS 5.
STEERING · 08E063000
2008-10-17
DORMAN PRODUCTS IS RECALLING 3,900 INTERMEDIATE STEERING SHAFTS DORMAN PART NOS. 425-151, 425-152, AND 425-153, (SOLD UNDER DORMAN'S "OE SOLUTIONS" BRAND NAME), BALKAMP #'S 7-3057, 7-3058, 7-3059 (SOLD UNDER THE "NAPA" BRAND NAME), AND PLATINUM PARTS #'S 2425151, 2425152, AND 2425153 MANUFACTURED DURING THE MONTH OF SEPTEMBER 2007. THESE REPLACEMENT STEERING SHAFTS CAN BE USED ON THE VEHICLES LISTED ABOVE. THE WELD CONNECTING THE INNER TUBE TO THE OUTER TUBE MAY BE DEFECTIVE.
Consequence: IF THE WELD FAILS, LOSS OF STEERING COULD RESULT, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: DORMAN WILL NOTIFY OWNERS AND REPLACE THE STEERING SHAFTS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 16, 2008. OWNERS MAY CONTACT DORMAN TOLL FREE AT 1-800-523-2492.
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.
SERVICE BRAKES, HYDRAULIC · 04V287000
2004-06-23
CERTAIN PASSENGER VEHICLES WERE PRODUCED WITH LOWER THAN SPECIFIED TORQUE ON BOTH FRONT BRAKE CALIPER TO STEERING KNUCKLE ATTACHMENT BOLTS. WITH IMPROPER TORQUE, THE CLAMP LOAD AT THE JOINT MAY NOT BE ADEQUATE TO PREVENT MOVEMENT BETWEEN THE CALIPER BRACKET AND KNUCKLE.
Consequence: DEPENDING ON WHETHER ONE OR BOTH BOLTS BACKS OUT OR FRACTURES, THE RESULT CAN BE LOCKING OF THE AFFECTED WHEEL DURING BRAKING AND AN ABRUPT STEERING INPUT IN THE DIRECTION OF THE LOCKED WHEEL, REDUCED BRAKING AND NOISE FROM THE AFFECTED WHEEL, OR SEVERING OF A BRAKE HOSE, INCREASED BRAKE PEDAL TRAVEL, AND REDUCED STEERING CONTROL. REDUCED BRAKING OR STEERING CONTROL COULD CAUSE A CRASH.
Remedy: DEALERS ARE TO TIGHTEN BOTH BOLTS TO THE SPECIFIED TORQUE. OWNER NOTIFICATION BEGAN ON JUNE 28, 2004. OWNERS SHOULD CONTACT CHEVROLET 1-800-630-2438 OR PONTIAC 1-800-620-7668.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.