This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
full bulletin at NHTSA ↗2005 Saturn Relay body problems
moderate 9 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Failure mileage
Complaints
9
Recalls
0
Avg fix
$1,500
When does it fail?
Of the 9 body complaints filed for the 2005 Saturn Relay, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA body complaint has been filed on this vehicle in over 16 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body 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 vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
full bulletin at NHTSA ↗THIS PRELIMINARY INFORMATION COMMUNICATION ADVISES THE TECHNICIAN THE STEPS ON DIAGNOSING THE CONCERN. VEHICLE'S SUNROOF OPERATION INTERMITTENT, BIND, NOISE, AUTO-REVERSE, AND/OR WATER LEAKS.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new
full bulletin at NHTSA ↗Underbody Component Corrosion The following information may be helpful when addressing underbody component corrosion with customers. Some customers may comment that one or more of their vehicle's underbody components are showing some form of corrosion. This corrosion may be red in appearance (rust) if the component is steel, forged iron or cast iron. This corrosion may also be grey or white in color if the component is constructed of an aluminum alloy.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 4 most recent
Tl* the contact owns a 2005 Saturn relay. While driving the rear sliding door opened without warning. He pulled over and it took 10 minutes to close the door. The vehicle was taken to the dealer, and the censors and motor were replaced. After the repair he experienced an identical failure. The vehicle was taken back to the dealer and repaired at his expense. None on the repairs have remedied…
Tl*the contact owns a 2005 Saturn relay. While driving 35 MPH, the door alarm sounds and indicates that both rear passenger doors are open. The contact must pull the vehicle over and close the doors. The manufacturer stated that the vehicle did not have any recalls; therefore, she would need to pay for a diagnostic. The contact will take the vehicle to the dealer. The failure mileage was…
Electric sliding door will open by itself on my 2005 Saturn relay. Have to disable door to be sure it does not open while driving, but will enable itself and start opening by itself again. As Saturn is out of business, do not know where to turn. *tr
We purchase the van march 2006 as the first owners. The original problem started in june of 2007 when the passenger side power sliding door would open back up when closing. We took the van to the dealer and they replaced the door jam switch. The mileage at the time was 11,584. From that time to now dec 2008, with 31,000 miles, the problem has continued and adding in the driver side power sliding…
Had body trouble with your 2005 Saturn Relay?
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 body problem on the 2005 Saturn Relay?
It's a documented issue but not catastrophic. 9 complaints have been filed. Repairs average $1,500 and most owners catch it before it causes a breakdown.
At what mileage does the body typically fail?
Across the 8 complaints that reported odometer mileage, most body failures cluster between 11,584 and 62,000 miles, with the median around 32,000. A quarter of owners report trouble before 11,584; a quarter make it past 62,000. 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 $1,500 for body 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 body?
No active recalls currently cover body 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/Saturn/Relay.
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.