This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
full bulletin at NHTSA ↗2005 Chevrolet Cobalt brakes problems
severe 20 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
20
Recalls
0
Avg fix
$450
6crashes
3injuries
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.
full bulletin at NHTSA ↗This informational bulletin provides technicians with a brake lathe calibration procedure.
full bulletin at NHTSA ↗This informational bulletin provides technicians with a brake lathe calibration procedure.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about vehicles that have a Service Engine Soon Malfunction Indicator Lamp. Technician may find Diagnostic Trouble Code P0442. Technician will need to review Techlink article from May 2013 titled "Using the Evaporative Emissions System Tester" Technician will need to follow these steps to help diagnose the issue. First after the P0442 has been verified do not disturb any of the fuel system components. The technician now can use the scan tool to close the Evaporative Emissions System. If possible change the tank pressure sensor units from inch_H2O to milimeter_Hg for better resolution. Now the vehicle can be star
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners describe multiple distinct brake system failures on this model year. The most serious: brake pedal goes soft on initial application, then goes hard or collapses to the floor with zero braking force, typically after 30+ minutes of highway driving at 55–75 mph. Several owners reported collisions when brakes completely failed to slow or stop the vehicle. One owner reported the pedal suddenly going "soft and then hard as a brick," resulting in hitting a pickup truck. Another described the brake pedal going straight to the floor with no pressure on an exit ramp at 60 mph, requiring emergency brake and downshift to stop.
Separately, owners report violent vibrations in the brake pedal and steering wheel after extended highway cruise control use (45+ minutes at 65+ mph), severe enough to require both hands on the wheel. Cruise control then malfunctions for hours or days afterward. ABS and traction control systems intermittently lock brakes up or fail to release; warning lights illuminate but extinguish when the vehicle is placed in park, preventing diagnostic code retrieval.
Additional brake issues include rear drum brake springs breaking (causing complete wheel lockup while moving), front rotors rusting prematurely at normal mileage, excessive rear brake wear and noise, and dash warning light false triggers. Multiple dealership visits and GM service centers have been unable or unwilling to diagnose and fix these problems, with GM refusing responsibility in several cases.
Same Chevrolet Cobalt brakes reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Brake pedal soft then hard / loss of braking pressure
Brake pedal becomes soft on initial application, then goes hard (rigid) or collapses to the floor, leaving no braking force. Occurs during active braking at highway speeds or during deceleration. Some narratives describe complete brake loss requiring emergency brake or downshift to stop vehicle.
When: Typically after 30+ minutes of highway driving at 55-75 mph; also reported sporadically without clear pattern
Symptoms owners cite: Brake pedal soft on first application; Brake pedal then goes hard or rigid; Brake pedal collapses to floor with no pressure; Vehicle does not slow down despite brake application; Multiple collisions result from brake failure
Codes mentioned: U0101
Repairs/costs cited: Master cylinder and ABS system replacement mentioned in one narrative; one owner reported missing bushing and clip at factory. Costs not consistently stated; one repair estimate was $500 for TCM replacement and reprogramming.
Recalls/TSBs owners mention: Recall campaign 10V073000 mentioned for steering (not directly brake-related); most dealers unable to duplicate the problem during short test drives
Violent brake vibration during deceleration from cruise control
Intermittent violent vibration of brake pedal and steering wheel when brakes applied after extended highway cruise control operation. Vibration severe enough to require both hands on wheel; lasts minutes to 15 miles. Cruise control malfunction follows vibration event.
When: After 45+ minutes at highway speeds over 65 mph with cruise control engaged; intermittent, sometimes does not occur
Symptoms owners cite: Violent vibration in brake pedal when first braking after cruise control; Violent steering wheel vibration requiring two-handed control; Increased vibration intensity with harder brake application; Cruise control becomes inoperative for 1 minute to 3 days after event; Vibration lasts minutes to 15 miles
Repairs/costs cited: Service manager acknowledged 'problem is in the brakes' but no repair performed; dealership determined nothing was wrong after short test drives.
Recalls/TSBs owners mention: Multiple dealership attempts (5 visits to 3 different dealers) unsuccessful; GM rep contacted but decided to do nothing; lemon law process initiated
ABS and traction control system malfunction with warning lights
ABS and traction control warning lights illuminate during driving; brake system locks up or fails to release after braking events. Lights persist intermittently and reset when vehicle placed in park, preventing diagnostic code retrieval.
When: Sporadic, no clear timing pattern; one incident after 10 minutes at 65 mph with cruise control
Symptoms owners cite: ABS and traction control warning lights illuminate during driving; Brakes lock up and fail to release; Brakes hold vehicle with locked grip requiring repeated pump cycling; Violent jerking at times with loss of vehicle control; Warning lights extinguish when vehicle placed in park; Smoke billowing from rear wheels during locked braking
Repairs/costs cited: Dealership unable to pull diagnostic codes when warning light not actively illuminated; problem recurs after repair attempts
Recalls/TSBs owners mention: Dealership recalled for recall campaign 10V073000 (steering); subsequent visits unable to resolve traction control issue
Rear drum brake spring breakage causing wheel lockup
Spring mechanism in rear drum brakes breaks, causing drum brake to lock fully in engaged position, stopping wheel rotation and dragging tire. Occurs on two separate occasions for same vehicle.
When: Reported on two occasions over couple of years; most recent on 6/25/2014
Symptoms owners cite: Spring mechanism breaks in rear drum brakes; Rear wheel locks up while driving; Tire dragged down road; Full brake engagement unintended
Repairs/costs cited: Over $300 in brake system damage from second occurrence
Recalls/TSBs owners mention: GM notified but refused to accept responsibility for defective spring mechanism
Rotor rusting and early deterioration
Front brake rotors rust out prematurely at low mileage, unable to be turned per standard service procedure. Multiple service centers report seeing this frequently on GM products and suspect manufacturing defect.
When: At 43,923 miles (normal wear mileage)
Symptoms owners cite: Front rotors rusted out; Rotors cannot be turned per standard brake service; Excessive rust buildup on new rotors
Repairs/costs cited: $84.48 plus labor for new rotor replacement
Recalls/TSBs owners mention: Dealership and independent service center both noted seeing this frequently on GM products; dealership stated uncertainty about cause
Brake light warning indicator malfunction
Brake light warning illuminates on dashboard momentarily or repeatedly without corresponding brake system failure. Dealership unable to duplicate problem.
When: Sporadic; mentioned as occurring several times after dealership repair attempt; early in vehicle ownership (2 days after purchase in one case)
Symptoms owners cite: Brake light warning illuminates on dashboard; Warning light comes on momentarily then disappears; No actual brake malfunction present when light activates
Repairs/costs cited: No repair completed; dealership unable to duplicate
Recalls/TSBs owners mention: Dealership explained no problem found; unable to diagnose
Rear brake wear accelerated
Rear brakes wear out abnormally fast and develop excessive noise.
When: <UNKNOWN>
Symptoms owners cite: Rear brakes wear quickly; Excessive noise from rear brakes
Synthesized from 20 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had brakes trouble with your 2005 Chevrolet Cobalt?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2005 Chevrolet Cobalt?
It's a meaningful issue. 20 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $450.
At what mileage does the brakes typically fail?
Across the 12 complaints that reported odometer mileage, most brakes failures cluster between 32,700 and 124,000 miles, with the median around 87,233. A quarter of owners report trouble before 32,700; a quarter make it past 124,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Chevrolet/Cobalt.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.