NHTSA vehicle safety data

2004 Volkswagen Passat Recalls, Ratings & Complaints

The 2004 Volkswagen Passat has 4 NHTSA recall campaigns and 277 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Volkswagen dealer.

NHTSA recall and complaint data for the 2004 Volkswagen Passat, plus NCAP crash-test ratings. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Volkswagen Passat owner complaints

Owners have filed 277 complaints with NHTSA about the 2004 Volkswagen Passat, describing incidents dated October 27, 2003 to July 30, 2025.

Most-cited components

Engine 76 complaints
Fuel/Propulsion System 57 complaints
Power Train 38 complaints
Seats 34 complaints
Electrical System 23 complaints
Exterior Lighting 16 complaints

Of the 277 complaints on file, 9 report a crash and 25 a fire; across all 277 complaints, owners report 23 injuries (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11677910 · Filed August 1, 2025
A fuel leak has developed from the top side of the fuel tank on the drivers side of me vehicle. A fuel leak in this manner is a serious critical and immediate safety risk. Recall 08V156000 was 'performed' on my vehicle back in 2008 but the exact same fuel system safety defect has returned. VW…
ODI #11662869 · Filed May 23, 2025
There was a recall reported by the manufacturer, Volkswagenm in 2008. There were multiple Fuel System issues: A Heat Shield that may contact the exhaust system and result in a vehicle fire; a fuel leak from a fuel line or fuel tank ventilation valve, in the presence of an ignition source, can lead…
ODI #11433670 · Filed September 20, 2021
The contact owns a 2004 Volkswagen Passat. The contact stated that there was gasoline leaking in his driveway where the vehicle was parked, after he had refueled the vehicle the day before. The vehicle was taken to an independent mechanic and the mechanic informed the contact that it was a known…

Read all 277 complaints

Owner-reported

2004 Volkswagen Passat mileage at failure

217 of the 277 complaints on file for the 2004 Volkswagen Passat give the vehicle's mileage when the problem happened.

Mileage at failure by component, from owners' complaints to NHTSA
Component	Median	Middle half	Based on
Engine	Median 80,000 miles	Middle half 55,000–110,000 miles	Based on 63 complaints
Fuel/Propulsion System	Median 90,000 miles	Middle half 70,000–130,000 miles	Based on 46 complaints
Power Train	Median 35,000 miles	Middle half 1,000–80,000 miles	Based on 33 complaints

A component's median is its 50th percentile, and its middle half runs from its 25th to its 75th percentile.

Owners give the mileage themselves, often as a round number, and NHTSA doesn't check it. A complaint that names several components counts under each one, and mileages that can't be right, such as 999,999, or 50 miles on a five-year-old car, are left out.

These figures describe the complaints owners filed. They don't predict when a particular vehicle will have a problem, and vehicles that never had one aren't counted.

Mileage from NHTSA's complaints file of October 31, 2026. How these figures are worked out

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Volkswagen Passat in 3 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Engineering Analysis EA11-002: Engine Compartment Fire
Closed February 17, 2012
Engineering Analysis EA07-014: PASSENGER ENGINE COMPARTMENT FIRES
Closed July 7, 2008
- Recall 08V-156
Preliminary Evaluation PE08-008: FUEL TANK LEAK
Closed May 30, 2008
- Recall 08V-156
- Recall 08V-157

Open and recently closed NHTSA defect investigations

Water Pump may cause Failure of Timing Belt

NHTSA #14E007000 · Engine and Engine Cooling — Engine · NHTSA notice

Reported March 7, 2014 · The Gates Corporation

Potentially affected: 50 vehicles

Repair completion: 2% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Owners notified May 1, 2014

Defect description

The Gates Corporation (Gates) is recalling certain aftermarket Tru-Flow Water Pumps, part number TFW 41127, sold at certain NAPA Auto Parts and/or installed by automotive service technicians after November 1, 2013 (and manufactured August 2013 through October 2013) that have a black-colored pulley/sprocket or do not have 'US9377' stamped on the water pump housing. These service replacement parts were sold for use in model year 1999-2005 Audi A4, 2000-2006 Audi TT, 1998-2005 Volkswagen Beetle, 1999-2006 Golf, 1999-2008 and 2011-2013 Volkswagen Jetta, and 2000-2005 Volkswagen Passat. In the affected water pumps, the pulley or sprocket that turns the timing belt may develop microfractures causing the timing belt to fail.

Safety consequence

A failure of the timing belt may cause the engine to shut down, potentially increasing the risk of a vehicle crash.

Manufacturer remedy

Gates will notify owners, and dealers will replace the water pump, free of charge. The recall began during May 2014. Owners may contact The Gates Corporation at 1-303-744-1911.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

UNDERBODY HEAT SHIELDS/FUEL SYSTEM COMPONENTS

NHTSA #08V156000 · Fuel System, Gasoline — Delivery · NHTSA notice

Reported April 7, 2008 · VOLKSWAGEN OF AMERICA, INC

Potentially affected: 412,000 vehicles

Volkswagen campaign 26E5/R5 · Owners notified June 13, 2008 · Vehicles built June 1, 1999 – May 31, 2005 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE.

Safety consequence

A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.

Manufacturer remedy

DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T VEHICLES AND THE FUEL TANK VENTILATION VALVE ON 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

Notes

VWOA RECALL NO. 26E5/R5.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

MALFUNCTIONING BRAKE LIGHT SWITCHES

NHTSA #07V063000 · Exterior Lighting — Brake Lights — Switch · NHTSA notice

Reported February 20, 2007 · VOLKSWAGEN OF AMERICA, INC

Potentially affected: 1,002,000 vehicles

Volkswagen campaign N4 · Owners notified April 27, 2007 · Vehicles built April 1, 2002 – April 30, 2005 (per NHTSA)

Defect description

ON CERTAIN PASSENGER, WAGON, AND CONVERTIBLE VEHICLES EQUIPPED WITH OR WITHOUT CRUISE CONTROL, A BRAKE LIGHT SWITCH MAY MALFUNCTION IF IT WAS INSTALLED INCORRECTLY.

Safety consequence

THE BRAKE LIGHTS COULD BECOME INOPERATIVE, OR REMAIN ON. FAILURE TO PROVIDE THE PROPER SIGNAL WHEN BRAKING COULD LEAD TO A CRASH WITHOUT WARNING.

Manufacturer remedy

DEALERS WILL INSTALL THE NEWLY DESIGNED BRAKE LIGHT SWITCH FREE OF CHARGE. THE RECALL BEGAN ON APRIL 27, 2007, AND WILL BE CONDUCTED IN SEVERAL STAGGERED MAILINGS THROUGH SEPTEMBER 21, 2007. VEHICLES WITHIN THE MAKE, MODEL, AND MODEL YEAR OF THIS POPULATION MAY BE INVOLVED IN EITHER THIS RECALL OR 06V-183, BUT NOT BOTH. THE REMEDY IS THE SAME FOR EACH RECALL. VOLKSWAGEN DEALERS WILL APPLY THE REMEDY BASED ON THE VIN NUMBER OF THE VEHICLE. OWNERS MAY CONTACT VW AT 1-800-822-8987.

Notes

VOLKSWAGEN RECALL NO. N4.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

VW/DIESEL PUMPS FASTENER

NHTSA #04V586000 · Fuel System, Diesel · NHTSA notice

Reported December 15, 2004 · VOLKSWAGEN OF AMERICA, INC

Potentially affected: 19,284 vehicles

Volkswagen campaign VY · Owners notified February 8, 2005 · Vehicles built March 1, 2004 – August 29, 2004 (per NHTSA)

Defect description

ON CERTAIN PASSENGER VEHICLES, THE HIGH PRESSURE DIESEL PUMPS WERE PRODUCED WITH AN IMPROPER FASTENER, WHICH COULD ALLOW DIESEL FUEL TO ESCAPE FROM THE PUMP.

Safety consequence

FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY LEAD TO A FIRE.

Manufacturer remedy

DEALERS WILL REPLACE THE DIESEL PUMP. THE RECALL BEGAN ON FEBRUARY 8, 2005. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

Notes

VW RECALL NO. VY.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

2004 Volkswagen Passat 4-DR. w/SAB

—

out of 5

Overall Safety Rating

Not Rated

Frontal Crash

Not Rated

Driver: 5, Passenger: 5

Side Crash

Not Rated

Driver: Not Rated, Passenger: Not Rated

Side Pole

Not Rated

Rollover

Not Rated

Safety Technology

Electronic Stability Control

3 investigations

277 owner complaints have been filed with NHTSA for the 2004 Volkswagen Passat.

Fuel/Propulsion System

ODI #11677910

Incident: July 30, 2025 · Filed: August 1, 2025

A fuel leak has developed from the top side of the fuel tank on the drivers side of me vehicle. A fuel leak in this manner is a serious critical and immediate safety risk. Recall 08V156000 was 'performed' on my vehicle back in 2008 but the exact same fuel system safety defect has returned. VW acknowledges the recall and claims it was completed while only an inspection to check for fuel leaks was performed at the time. VW Care and my local dealership refuse to address the ongoing issue. This poses a continued fire risk, and I am now being told to pay out of pocket for a known safety recall that clearly failed to remedy the original defect.

Fuel/Propulsion System

ODI #11662869

Incident: March 14, 2025 · Filed: May 23, 2025

There was a recall reported by the manufacturer, Volkswagenm in 2008. There were multiple Fuel System issues: A Heat Shield that may contact the exhaust system and result in a vehicle fire; a fuel leak from a fuel line or fuel tank ventilation valve, in the presence of an ignition source, can lead to a vehicle fire. In 2008, my car was inspected and the recall was deemed "complete." However, the car was only 4 years old at the time and no repairs were made. Only a visual inspection was done. I bought the car used 6 years ago, and it has been diagnosed as having a defective fuel tank ventilation valve. VW should pay for the parts and labor to have this fixed because it was never fixed. I've been told there's no statue of limitations on recalls. VW claims that because the recall was deemed "Complete" that they "fixed" the issue but they didn't.

Fuel System, Gasoline

ODI #11433670

Incident: September 19, 2021 · Filed: September 20, 2021

The contact owns a 2004 Volkswagen Passat. The contact stated that there was gasoline leaking in his driveway where the vehicle was parked, after he had refueled the vehicle the day before. The vehicle was taken to an independent mechanic and the mechanic informed the contact that it was a known failure related to NHTSA Campaign Number: 08V156000 (Fuel System, Gasoline). The dealer and manufacturer were made aware of the failure but informed the contact that the failure was addressed in 2012 and the recall was closed on the VIN. The failure mileage was 97,361.

Fuel/Propulsion System

ODI #11396511

Incident: September 12, 2019 · Filed: February 16, 2021

WHEN YOU FILL UP THE FUEL TANK IT LEAKS IT LEAKS A QUARTER OF A TANK OF FUEL ROUGHLY 4 TO 5 GALLONS OF FUEL DRIP OUT THERE'S A FACTORY RECALL ON THIS ISSUE I TOOK IT TO THE VOLKSWAGEN DEALER PAID MONEY TO HAVE THEM INSPECT IT AND THEY SAID YES IT'S LEAKING AT THE FACTORY RECALL I'VE HAD AN INDEPENDENT DEALER CONFIRM THAT! VOLKSWAGEN WILL NOT DO ANYTHING DUE TO WHAT THEY CLAIM A REMEDY WAS DONE BY MOVING FUEL LINES 10 YEARS AGO, OBVIOUSLY IT WAS NOT OR I WOULD NOT HAVE 4 GALLONS OF FUEL SPILL IN MY DRIVEWAY VEHICLE IS BASICALLY IN OPERABLE AND THEY WANT $3000 TO PUT A NEW FUEL TANK IN WHEN IT'S A FACTORY RECALL WHICH NEVER EXPIRES I HAVE TALK TO THE VOLKSWAGEN REP AND THE ONLY THING I HAVE FOUND IN FORUMS IS DO YOU HAVE TO GO TO VOLTS WAGON OF AMERICA AND FIGHT THEM AND THIS IS RIDICULOUS WHEN THEY KNOW THEY HAVE AN ISSUE!! TO DRIVE THIS VEHICLE WE NEVER FILL IT OVER A HALF A TANK OF FUEL SO WE DO NOT LEAK FUEL OR EXPLODE WHILE WE'RE DRIVING HOPEFULLY PLEASE HELP IN ANYWAY YOU CAN THANK YOU

Seats

ODI #11395719

Incident: December 26, 2020 · Filed: February 11, 2021

A COIL FOR HEATED SEATS HAS MELTED A HOLE IN THE DRIVER'S SIDE SEAT. THIS CAUSED PAIN AND CONFUSION WHILE DRIVING ON THE HIGHWAY. THE SEAT NOW HAS AN UGLY MELTED HOLE IN IT.

Seats

ODI #11373531

1 injury

Incident: November 4, 2020 · Filed: November 6, 2020

WHILE DRIVING ON A HIGHWAY, THE DRIVER SEAT SUDDENLY OVERHEATED (THE SEAT WARMER WAS TURNED ON). IT STARTED WITH A BURNING SMELL. EXCESSIVE HEAT BURNED MY LEG A BIT (SOME SKIN REDNESS), BEFORE I REALIZED WHAT IS HAPPENING AND TURNED THE SEAT WARMER OFF. THE SEAT LEATHER NOW APPEARS STIFF AND WRINKLED (NOT SOFT AND SMOOTH LIKE THE REST OF THE LEATHER) IN THE AREA WHERE I FELT THE HEAT.

Seats; Fuel/Propulsion System

ODI #11319272

Incident: March 25, 2020 · Filed: March 25, 2020

THE CAR STALLED IN THE ROAD. PULLED OVER. TURNED THE CAR OFF AND IT WOULD NOT RESTART FULL TANK OF GAS.

Seats; Unknown or Other

ODI #11269771

Incident: October 19, 2019 · Filed: October 20, 2019

MY CAR 2004 VW PASSAT ALMOST GETT ON FIRE FRONT PASSANDER SEAT HAVE START TO BURN BUT WAS OK AFTER I SHUTT OFF THE CAR AFTER THAT NOW I CAN DRIVE BUT THE SEAT ITS DEMAGED

Engine

ODI #11229463

Incident: July 1, 2019 · Filed: July 4, 2019

WHILE DRIVING THE CAR AT HIGHWAY SPEEDS IT STALLS AND THE EPC LIGHT COMES ON. THIS HAS HAPPENED MANY TIMES WHILE MERGING WITH OTHER TRAFFIC AND CAN BE VERY DANGEROUS. I HAVE SPENT WELL OVER $1000 TRYING TO GET THIS PROBLEM FIXED, AND THE PROBLEM STILL REMAINS. EVEN THE VW DEALERSHIP DOSE NOT HAVE AN ANSWER.

Fuel/Propulsion System

ODI #11157192

Incident: November 2, 2018 · Filed: December 9, 2018

STRONG ODOR OF FUEL IN THE CAR REGARDLESS OF BEING PARKED OR MOVING. NOTICED PUDDLE OF GAS ON THE GROUND UNDER THE FUEL TANK. FUEL WAS DRIPPING DOWN OFF THE FUEL TANK AND THE HEAT SHIELDS. FOLLOWED DRIP TO THE ROLLOVER VALVE NIPPLE WHICH IS ATTACHED TO THE GAS TANK.

Other Volkswagen Passat model years

Check your 2004 Volkswagen Passat VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Volkswagen Passat at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

Check a Volkswagen VIN