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 Saturn Relay brakes problems
severe 32 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Failure mileage
Complaints
32
Recalls
0
Avg fix
$450
2crashes
When does it fail?
Of the 32 brakes 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
Brakes accounts for 35% of every owner complaint on file for this vehicle — the dominant problem area across 8 categories tracked.
Owners have filed 32 brakes complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
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
This 2005 Saturn Relay has a consistent pattern of ABS and brake system failures across 32 complaints. The most common issue is the ABS/traction control system throwing warning lights intermittently or continuously, with lights coming on at random times regardless of weather or road conditions. Multiple owners report the system engages the brakes without any pedal input, causing sudden deceleration, tire squealing, and vehicle pulling at highway speeds. One owner disabled the ABS fuse as a workaround after a GM-certified mechanic identified the electronic brake control module (EBCM) as the culprit.
Brake rotor warping is another recurring defect. Rotors fail prematurely—often within 10,000 to 25,000 miles—causing severe vibration and grinding during braking. Dealers resurfacing or replacing rotors has not fixed the problem; the rotors warp again shortly after repair, some owners replacing them multiple times yearly.
Multiple owners report unintended brake engagement—brakes applying without foot on pedal or losing pedal firmness entirely. One owner experienced sudden acceleration instead of braking while parking (twice during left turns), taking out playground equipment before stopping.
Wheel speed sensors and ABS hub sensors fail repeatedly. One owner had sensors replaced five times before discovering the real problem was a faulty EBCM. Dealers replaced hubs, sensors, BCM modules, and even the ABS pump in various vehicles, yet identical failures recurred after repairs.
Failure modes owners describe
ABS/Traction Control System Malfunctions
ABS and traction control warning lights illuminate intermittently or continuously, often requiring repeated diagnostic visits. Many owners report the lights come on at random times with no correlation to weather or road conditions, and turning the vehicle off and back on may temporarily clear the lights. The system intermittently engages the brakes without driver input, causing sudden deceleration, vehicle pulling, or tire squealing. In several cases, owners report the system actually fails to function when needed (in snow) while activating inappropriately in dry conditions.
When: Varied; some reports at specific mileages (17,700 to 184,000 miles), others intermittent from early ownership
Symptoms owners cite: ABS/traction control warning lights illuminate intermittently or remain on; Brakes engage without driver applying pedal; Vehicle veers left or right when system engages; System fails to activate in adverse weather when needed; Lights temporarily clear by power cycling vehicle; Traction control engages on dry roads without trigger
Codes mentioned: EBCM (Electronic Brake Control Module) fault, Wheel speed sensor codes, ABS system codes
Repairs/costs cited: Dealers have replaced EBCM modules (cost cited over $1,000 in one case), ABS pump, BCM, wheel hubs with sensors, and wheel speed sensor jumper wiring. One owner had ABS fuse removed as workaround. Many repairs have not resolved the problem; owners report identical failures recurring after dealer repairs.
Recalls/TSBs owners mention: Saturn dealerships have referenced Technical Service Bulletin 0108450050 in at least one case. GM dealer replaced EBCM but owner reports problem persists.
Unintended Brake Engagement / Loss of Brake Control
On multiple occasions, brakes have engaged or failed when not requested by the driver, or brake pedal has lost firmness and extended to floorboard. One owner experienced sudden acceleration instead of braking while attempting to park (two separate incidents, both during left turns). Another reported brakes engaging at highway speed with foot not on pedal, causing vehicle to lurch and tire squealing. A third owner felt brakes shutting down and nearly ended up in a river with a child in the vehicle.
When: Varied; one owner reports at approximately 17,700 miles on first incident; incidents span early to later ownership
Symptoms owners cite: Brake pedal goes to floorboard when depressed; Brake pedal loses firmness and shutters; Brakes engage without driver pressing pedal; Vehicle accelerates when brakes applied (two incidents both during left turns); Loss of steering when brake issues occur; Sudden deceleration and vehicle pulling during unintended engagement
Codes mentioned: EBCM fault codes
Repairs/costs cited: One dealer cleaned plugs but failure continued. Brake fluid leak found in rear caliper (unrelated to core issue). Problem persisted despite multiple dealer visits. No successful repairs documented.
Brake Rotor Warping and Premature Wear
Rotors warp repeatedly and prematurely, often within 10,000-25,000 miles or even after resurfacing. Warping occurs both during normal driving and especially when descending mountains or during extended braking. Owners report severe vibration and grinding sounds when braking after rotor warping occurs. Rotors have been resurfaced or replaced multiple times on single vehicles without permanent resolution.
When: Early in ownership; rotor failures reported as early as 15,000 miles, continuing to recur every 10,000 miles or less
Symptoms owners cite: Rotors warp causing brake vibration and shaking; Loud grinding or rumbling noise during braking; Brake pulsation when pedal depressed; Wheels locked up on one occasion; Excessive vibration during braking; Rotors warp again shortly after resurfacing or replacement
Repairs/costs cited: Dealers have resurfaced or replaced rotors and brake pads multiple times. One owner replaced brakes twice per year. Resurfacing has not permanently resolved the issue; rotors warp again after dealer repair.
Wheel Speed Sensor / ABS Hub Sensor Failures
Wheel speed sensors and ABS hub sensors fail repeatedly, requiring multiple replacements on single vehicles. One owner had sensors replaced five times due to AWD being disabled by false ABS warnings, only to discover later the actual problem was the EBCM, not the sensors. Loose female terminals in sensor connectors are noted in service bulletins.
When: Variable; one owner reports first replacement at around 60,000 miles, then recurring within months
Symptoms owners cite: ABS warning light illuminates; AWD disabled by false sensor codes; Intermittent ABS warning lights at various speeds
Codes mentioned: ABS wheel speed sensor codes, Bad sensor codes (often misdiagnosed; actual fault may be EBCM)
Repairs/costs cited: Hub/wheel speed sensors replaced multiple times (one owner: five replacements). Service includes checking female terminals in sensor connectors and packing connector with grease per TSB 0108450050. Repeated sensor replacements have not resolved underlying problem in multiple cases.
Recalls/TSBs owners mention: Technical Service Bulletin 0108450050 guides connector inspection and grease packing procedure.
Brake Pedal Vibration and Pulsation
Brake pedal vibrates or pulsates when pressed, often at higher speeds. One owner experienced significant vibration that was addressed with rotor machining and then rotor/pad replacement, but the failure recurred.
When: Various speeds from 5 MPH to highway speeds; one failure documented at 23,000 to 48,900 miles
Symptoms owners cite: Brake pedal pulsates when depressed; Excessive vibration when braking; Vibration especially noted at higher speeds
Repairs/costs cited: Rotors have been machined or replaced and brake pads replaced. Vibration recurred after repairs.
Synthesized from 32 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 6 most recent
Failure of sliding side door to lock failure of windshield wipers failure of rear brakes. *tr
2005 Saturn relay has numerous design flaws, and Saturn is unable to fix. Onstar disables speedometer when used, radio mutes and car must be turned off and back on to reset, ABS system malfunctions repeatedly even after replacing ebcm, ABS pump, BCM, lights flicker both interior and exterior, alternator found to have erratic output, new alternator did not solve problem. Brake rotors warped…
Dt: the contact states there was an ongoing problem with exterior and interior lighting. While driving, the headlights and the dashboard panel lights flickered from bright to dim. Also, the idle was very loud and rough. She took the vehicle to the dealer. The dealer replaced the alternator. This did not correct the problem. The dealer was unable to accurately diagnose the problem, and no…
I have a Saturn relay with brake problems. The ABS does not work properly. Very scary stuff. The ABS will come on with dry conditions but will not come on when we actually need them, like in the snow. Saturn does not know what the issue is. Keep taking my van back and nobody seems to know how to fix it. I guess there waiting for me and my children to actually get into a serious accident…
I bought a used 2005 Saturn relay 3 in january 2010. I have 2 major issues going on: power sliding doors will not recognize that they are closed and will continue to ding as if I was driving with them open...on a few occasions I have heard the power door motor start on its own as if it was trying to open the doors while I am driving! Second issue is ABS/traction control lights have been coming…
On sunday, november 9, 2008 I was backing up in my driveway when the traction control engaged briefly, stopped and the service light for both the tc and the ABS remained on. I have not been able to get rid of the service lights. On monday I brought the van into the local garage. In june 2008, I had the same problem but the service lights turned off. The same garage put in new ball bearings…
Had brakes 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 brakes problem on the 2005 Saturn Relay?
It's a meaningful issue. 32 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 29 complaints that reported odometer mileage, most brakes failures cluster between 17,700 and 73,548 miles, with the median around 39,500. A quarter of owners report trouble before 17,700; a quarter make it past 73,548. 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/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.