This informational bulletin instructs the tech when fuel/fluid is needed to be tested and where it can be sent for analysis.
full bulletin at NHTSA ↗2016 Chevrolet Malibu brakes problems
severe Owners of the 2016 Chevrolet Malibu have filed 54 NHTSA complaints about the brakes, typically surfacing around 70,000 miles at roughly $450 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See brakes across all vehicles →
Failure mileage
Complaints
54
Recalls
0
Avg fix
$450
| Model year | brakes complaints |
|---|---|
| 2012 Malibu | 24 |
| 2013 Malibu | 26 |
| 2014 Malibu | 14 |
| 2015 Malibu | 6 |
| 2016 Malibu (this page) | 54 |
| 2017 Malibu | 40 |
| 2018 Malibu | 40 |
| 2019 Malibu | 15 |
| 2020 Malibu | 26 |
9crashes
6injuries
When does it fail?
Of the 54 brakes complaints filed for the 2016 Chevrolet Malibu, 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
Of the 16 model years of Chevrolet Malibu we track for brakes problems, this one carries the most owner complaints on file — 54.
Owners have filed 54 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 bulletin advises the dealers to maintain the vehicle stock on hand by doing a full inspection on the vehicles before being sold (prepping) to the customer.
full bulletin at NHTSA ↗This bulletin advises the dealers to maintain the vehicle stock on hand by doing a full inspection on the vehicles before being sold (prepping) to the customer.
full bulletin at NHTSA ↗This service bulletin provides diagnostic/repair information to correct customer concerns of a Crank No Start or Extended Crank, Malfunction Indicator Lamp (MIL) Illuminated or Possible Increased Brake Pedal Effort.
full bulletin at NHTSA ↗This Preliminary information communicates that when removing the fuel line jumper hose care should be taken to be sure the line is reinstalled correctly to avoid a no/low fuel pressure situation.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The most common brake failure is vacuum pump collapse, reported by owners from 4,100 to 145,000 miles. The pump quits abruptly with no warning light, the brake pedal becomes rock-hard, and the car won't stop. Owners describe having to pump the pedal for minutes or use the parking brake to avoid collisions. The pump can fragment and contaminate engine oil, requiring $1,986 to $4,500+ in repairs. Owners report the pump fails again after dealer replacement, sometimes within three months, and say a class-action lawsuit exists over this defect. GM redesigned the pump to prevent breakaway pieces, proving Chevrolet knows about the issue.
Electronic brake control module (EBCM) and ABS failures leave owners with manual braking only. Brakes lock up, the car skids or loses steering control, and all four rotors overheat to 240 degrees. The ABS or StabiliTrak light comes on—or doesn't, leaving owners unaware. Owners cite an existing recall (39440) that does not include their vehicles despite identical failure modes.
Brake pedal hardening, stiffening, and sensor failures also cause extended stopping distance and crashes. One owner crashed at 15 mph; the airbag partially deployed but did not protect. Another needed a tow on the Pennsylvania Turnpike with children in the car. Multiple owners report dealerships cannot duplicate the failure or offer no repair, and repair parts are no longer in production.
Same Chevrolet Malibu brakes reports on nearby years: 2013 · 2014 · 2017 · 2018 · 2019
Failure modes owners describe
Brake Booster / Vacuum Pump Failure
The brake vacuum pump fails, causing a sudden loss of brake assist. The brake pedal becomes extremely hard to depress, requiring excessive force. In some cases the pedal travels to the floorboard with no braking effect. Owners report grinding or loud thumping noises from under the hood when the failure occurs. The pump can shed internal pieces that contaminate the engine oil and damage internal components like the camshaft and timing chain.
When: Can occur at any mileage from ~4,100 miles to 145,000+ miles; most commonly reported between 30,000 and 100,000 miles. Some failures repeat after initial replacement.
Symptoms owners cite: Brake pedal becomes very hard or stiff to depress; Brake pedal travels to the floorboard; Loss of braking power or extended stopping distance; Loud grinding, thumping, or gushing noises from under the hood when braking; Check engine light illuminates; Brake pedal does not respond or responds very slowly; Reduced engine power warning message; Engine overheating and smoking (from debris in engine)
Codes mentioned: P0556 (Brake Booster Pressure Sensor), P2097, P050F, P2138, FE8 and FE9 (engine codes related to valve timing)
Repairs/costs cited: Vacuum pump replacement; costs cited $1,986 to $4,500+. Engine replacement may be necessary if pump fragments contaminate oil and damage internal engine components. One owner reported repair cost of $180/hour labor with 12 hours per component. Parts difficult to source, new or used.
Recalls/TSBs owners mention: Recall 39440 exists but affects only specific production dates; owners outside the recall window report their VINs are not included despite identical symptoms. GM has redesigned the pump to eliminate the breakaway component. No recall expansion announced. Extended warranty may or may not cover damage from pump failure.
ABS / Electronic Brake Control Module (EBCM) Failure
The ABS system or electronic brake control module fails, causing loss of anti-lock braking and traction control. The vehicle may lock up, skid, or lose steering control in emergency braking or wet conditions. ABS and StabiliTrak warning lights illuminate. Brakes may drag, pulsate, or fail to engage properly. Some owners report wheels reaching extreme temperatures (240 degrees).
When: Reported from ~14,000 miles to 144,000+ miles; intermittent initially, then becoming consistent.
Symptoms owners cite: ABS warning light illuminates; StabiliTrak / traction control warning light illuminates; Loss of ABS function, reverting to manual braking only; Brake pedal vibrates briefly then goes to floor; Vehicle locks up or skids during braking; Loss of steering control; Vehicle drifts or floats across the road; All four brakes dragging or pulsing; Brake rotors overheat (240 degrees reported)
Codes mentioned: U0415-71 (Invalid Data Received From Electronic Brake Control Module), NHTSA Campaign 16V272000 (Electronic Stability Control)
Repairs/costs cited: ABS control module or EBCM replacement required. One owner's vehicle was towed; another reported the failure could not be diagnosed or duplicated by dealers, leaving vehicle unrepaired.
Recalls/TSBs owners mention: Recall 39440 documented for EBCM failure on 2016 Malibus with specific production dates. Owners outside the recall window report VINs not included despite identical failure symptoms. Dealers state vehicles are 'not included in a recall' and refuse diagnosis.
Brake Master Cylinder Failure
The brake master cylinder fails, rendering the brakes inoperable or severely compromising braking performance. The pedal may go soft, require excessive force, or fail to engage. One owner reported parts are no longer in production, preventing repair.
When: Reported at approximately 75,000 miles.
Symptoms owners cite: Brakes inoperable or severely degraded; Brake pedal soft or unresponsive; Extended stopping distance; Intermittent failure that cannot be duplicated
Repairs/costs cited: Brake master cylinder replacement required. One owner was informed repair parts are no longer in production and vehicle could not be repaired.
Brake Pedal Sensor / Booster Pressure Sensor Failure
The brake booster pressure sensor fails, causing the brake system to malfunction. Check engine light illuminates with brake booster pressure sensor error code. Braking performance degrades or becomes unpredictable.
When: Reported at 32,000 miles, 62,114 miles, and 90,319 miles.
Symptoms owners cite: Check engine light illuminates; Brake booster pressure sensor error code present; Brakes fail to engage or operate erratically; Brake pedal may seize or travel to floorboard; Loss of power or vehicle slowdown
Codes mentioned: P0556 (Brake Booster Pressure), P2138 (Throttle/Pedal Position Sensor)
Repairs/costs cited: Brake pedal sensor or booster pressure sensor replacement. One owner was told a new brake pedal sensor needed installation.
Recalls/TSBs owners mention: Manufacturer notified in at least one case but provided no assistance.
ABS Malfunction Without Warning Lights
The ABS system engages or malfunctions unexpectedly without illuminating warning lights on the dashboard. Vehicle jerks or pulsates under braking. The failure occurs at very low speeds and can be repeated.
When: Reported at very low mileage (61 miles) and at 61,000 miles.
Symptoms owners cite: ABS engages without warning at very low speeds; Vehicle jerks repeatedly during gradual braking; No warning lights illuminate; Failure repeats across multiple brake applications
Repairs/costs cited: One dealer was unable to diagnose any failure despite the symptom repeating.
Recalls/TSBs owners mention: Manufacturer notified; no outcome reported.
Brake System Grinding / Noise with No Diagnosis
Brake system produces loud grinding noises during braking, suggesting mechanical wear or contamination, but dealers cannot identify the cause and attribute it to 'moisture.' The noise persists for years despite multiple dealership visits.
When: Reported three weeks after purchase (at very low mileage) and intermittently for years thereafter.
Symptoms owners cite: Loud grinding or scraping noise during braking; Noise occurs occasionally or intermittently; Noise lasts a few seconds per occurrence; Noise continues for years despite dealership inspections
Repairs/costs cited: No repair identified or completed. Dealerships attributed noise to moisture buildup.
Recalls/TSBs owners mention: Dealerships offered no remedy.
Brake Pedal Hardening / Stiffening
The brake pedal becomes abnormally hard or stiff without warning, requiring excessive force to depress. This can occur suddenly during normal driving. In some cases it results in crashes because the owner cannot stop the vehicle in time.
When: Reported from 15 mph to 65 mph driving speeds; one crash at 25 mph, another at 15 mph.
Symptoms owners cite: Brake pedal suddenly becomes very hard or stiff; Excessive force required to depress the pedal; Extended stopping distance; No warning lights or prior indication; Failure can result in collision
Repairs/costs cited: One owner crashed into another vehicle at 15 mph due to hardened brake pedal; driver-side airbag failed to deploy properly. Another owner used the parking brake and manual steering to avoid collision.
Synthesized from 54 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Vehicle purchased in september 2015 with 18 miles. 3 weeks later when brakes were pressed, they started making this grinding sound. The sound appeared occasionally every few months for a few seconds. Brake noise still occasionally occurring in 2019, dealerships said it's just moisture. Think it's something else. 3 weeks after purchase engine light comes on with code p2097, then light cuts off a…
Tl* the contact owns a 2016 Chevrolet malibu. While driving 25 MPH, the brake pedal traveled to the floorboard when it was depressed. The wheels locked up and the contact's vehicle slid into the rear of the preceding vehicle. The air bags failed to deploy. A police report was filed and there were no injuries. The vehicle was towed to an independent repair facility for repairs. The manufacturer…
Had brakes trouble with your 2016 Chevrolet Malibu?
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 2016 Chevrolet Malibu?
It's a meaningful issue. 54 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 32,000 and 100,000 miles, with the median around 70,000. A quarter of owners report trouble before 32,000; a quarter make it past 100,000. 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/2016/Chevrolet/Malibu.
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.