VOLKSWAGEN PASSAT · model year

2004 VOLKSWAGEN PASSAT

348 NHTSA complaints, 12 crash reports, and 4 active recalls for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2004VOLKSWAGENPASSAT carries 348 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 12 crashes, 31 fires, 27 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 PASSAT is engine and engine cooling with 33 filings, followed by power train:automatic transmission (22) and fuel/propulsion system (22). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 4 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle, the full NHTSA campaign numbers are listed below.

NHTSA currently has 37 investigation files overlapping the 2004 PASSAT, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page, a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

348
Complaints
12
Crashes
31
Fires
27
Injuries
0
Deaths

Total Complaints

348 filings

Crashes Reported

12 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

Above median complaint volume, review patterns below.

Complaints by Component

ComponentCount
ENGINE AND ENGINE COOLING33
POWER TRAIN:AUTOMATIC TRANSMISSION22
FUEL/PROPULSION SYSTEM22
FUEL SYSTEM, GASOLINE21
SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER20
ENGINE AND ENGINE COOLING:ENGINE18
ENGINE18
ELECTRICAL SYSTEM16
SEATS15
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)9
STRUCTURE9
STRUCTURE:BODY7
EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH7
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP6
UNKNOWN OR OTHER6

Recalls (4)

07V06300020/02/2007

EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH

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

04V58600015/12/2004

FUEL SYSTEM, DIESEL

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.

08V15600007/04/2008

FUEL SYSTEM, GASOLINE:DELIVERY

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

14E00700007/03/2014

ENGINE AND ENGINE COOLING:ENGINE

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/s

Recent Complaints

20250801FUEL/PROPULSION SYSTEM

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.

20250523FUEL/PROPULSION SYSTEM

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.

20210920FUEL SYSTEM, GASOLINE

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.

Mileage: 97,361

20210216FUEL/PROPULSION SYSTEM

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

Mileage: 170,000

20210211SEATS

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.

Mileage: 160,000

20201106SEATS

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.

Mileage: 132,400

20200325FUEL/PROPULSION SYSTEM

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

Mileage: 195,000

20200325SEATS

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

Mileage: 195,000

20191020SEATS

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

20191020UNKNOWN OR OTHER

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

20190704ENGINE

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.

Mileage: 220,000

20181209FUEL/PROPULSION SYSTEM

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.

Mileage: 162,321

20180924FUEL/PROPULSION SYSTEM

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. AFTER REFUELING AND PARKING THE VEHICLE, THE CONTACT LATER DISCOVERED FUEL HAD LEAKED OUT FROM THE VEHICLE ONTO THE FLOOR OF THE GARAGE. FUEL WAS ALSO VISIBLE UNDERNEATH THE REAR SEAT OF THE VEHICLE. UPON INSPECTION, THE CONTACT DISCOVERED THAT FUEL WAS LEAKING FROM THE FUEL VALVE. THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE, BUT THE LOCAL DEALER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 160,000.

Mileage: 160,000

20180801UNKNOWN OR OTHER

STANDING WATER IN DRIVER SIDE AND REAR DRIVER SIDE AREA.

Mileage: 204,000

20180611FUEL/PROPULSION SYSTEM

GAS TANK/ FUEL LINE FRACTURE, LEAKING GAS WHEN I FILL IT UP, STRONG GAS SMELL/ODOR. STOPS LEAKING AT AROUND 3/4 TANK. VERY DANGEROUS FOR MY 16 YEAR OLD TO DRIVE. VW DEALERSHIP REFUSED TO CORRECT, WANTS TO CHARGE ME 2600, TO FIX I BOUGHT THE CAR FOR 4200 3 MONTHS AGO.

Mileage: 135,000

20180606FUEL/PROPULSION SYSTEM

GAS FUEL LINE/TANK LEAKING GAS

Mileage: 130,000

20180603FUEL/PROPULSION SYSTEM

FUEL TANK LEAK. THERE IS NO DAMAGE NO IMPACT NO VISIBLE EVIDENCE OF ANY MISUSE OF CAR. FUEL TANK LEAKS WHEN FILLED ABOVE 3/4 OF A TANK. THIS IS UNSAFE AND VERY DANGEROUS THIS SHOULD BE REPAIRED BY VOLKSWAGEN. IN ALL MY LIFE AS A MECHANIC I HAVE NEVER SEEN ANYTHING THIS UNSAFE. IF MY LOVED ONES WERE TO GET HURT I WILL HOLD VOLKSWAGEN ACCOUNTABLE. THIS NEEDS TO FIXED NOW!..

Mileage: 56,000

20180522FUEL/PROPULSION SYSTEM

LEAKING AT VENT/TOP OF GAS TANK. EXACTLY THE SAME DESCRIPTION OF THAT PAST HEAT SHEILD/VENT GAS LEAKING RECALL FROM ABOUT 10 YEARS AGO

Mileage: 130,000

20180515ENGINE

BOUGHT THIS CAR FROM ORIGINAL OWNER EXACTLY TWO YEARS AGO. ALL RECEIPTS FOR UPKEEP & MAINTENANCE WERE AVAILABLE. CAR RAN GREAT FOR 30,000 MILES. ONE DAY IT STARTING RUNNING BAD WITHIN 30 MINS WHOLE MOTOR SHUT DOWN. MOTOR JUST SHUT DOWN IN MIDDLE OF HIGHWAY. PIECE OF METAL FOUND UNDER VALVE COVER AND NOW FOR NO REASON NEEDS A WHOLE NEW MOTOR!!!! THIS IS A SERIOUS ISSUE! VERY DISSATISFIED! I HAVE OWNED THREE VEHICLES ALL FOR MORE THAN 10 YEARS UNTIL THIS VW AND NOW AM WITHOUT A CAR. NEVER WILL BUY OR MENTION ANYONE ELSE BUYING A VW. CANNOT AFFORD TO SPEND $3,000 FOR ANOTHER MOTOR AFTER ONLY OWNING FOR 2 YEARS! NOW THE CAR SITS AT A MECHANIC SHOP WITH NEW TIRES AND NEW VALVE COVER GASKETS AND A POS MOTOR.

Mileage: 164,000

20171130FUEL/PROPULSION SYSTEM

THE CAR DIED AS I WAS DRIVING DOWN A CITY ROAD, I WAS ABLE TO VEER THE CAR TO THE SIDE OF THE ROAD AS IT WAS ROLLING BEFORE IT STOPPED COMPLETELY. I HAD THE CAR TOWED BACK TO MY HOUSE AND AFTER TESTING ALL COMPONENTS, IT WAS DETERMINED THAT THE CAR WASN'T GETTING ANY FUEL DUE A FAULTY FUEL PUMP.

Mileage: 100,000

Compare 2004VOLKSWAGENPASSAT to Similar Vehicles

NHTSA Investigations 2 Open

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Frequently Asked Questions

How many complaints does the 2004 VOLKSWAGEN PASSAT have?
The 2004 VOLKSWAGEN PASSAT has 348 NHTSA complaints, 12 crashes, 31 fires, 27 injuries, and 0 deaths reported.
Are there any recalls for the 2004 VOLKSWAGEN PASSAT?
Yes, the 2004 VOLKSWAGEN PASSAT has 4 recall(s). The most common affected component is EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 VOLKSWAGEN PASSAT?
The most-complained component for the 2004 VOLKSWAGEN PASSAT is ENGINE AND ENGINE COOLING with 33 complaints. Other frequently reported areas include POWER TRAIN:AUTOMATIC TRANSMISSION and FUEL/PROPULSION SYSTEM.
Is the 2004 VOLKSWAGEN PASSAT safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.