This preliminary informational (PI) bulletin provides information to dealership personnel that may be helpful when addressing underbody component corrosion with customers.
full bulletin at NHTSA ↗2016 Chevrolet Malibu suspension problems
severe Owners of the 2016 Chevrolet Malibu have filed 18 NHTSA complaints about the suspension, typically surfacing around 67,335 miles at roughly $900 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See suspension across all vehicles →
Failure mileage
Complaints
18
Recalls
0
Avg fix
$900
| Model year | suspension complaints |
|---|---|
| 2012 Malibu | 4 |
| 2013 Malibu | 65 |
| 2014 Malibu | 8 |
| 2015 Malibu | 3 |
| 2016 Malibu (this page) | 18 |
| 2017 Malibu | 9 |
| 2018 Malibu | 10 |
1crash
What stands out
Among the 15 model years of Chevrolet Malibu in our records for suspension problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering suspension 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 service bulletin provides information on Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles.
full bulletin at NHTSA ↗This service bulletin provides information to dealership personnel on diagnosis and replacement of shock absorber and strut due to fluid leak.
full bulletin at NHTSA ↗This service bulletin provides information to dealership personnel on diagnosis and replacement of shock absorber and strut due to fluid leak.
full bulletin at NHTSA ↗This service bulletin provides technicians with information to help identify the differences between what is considered a fluid leak, and what is considered fluid seepage.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The most consistent complaint is a metallic popping or thumping noise from the rear suspension, reported at mileages starting around 28,000 miles and continuing through 96,000+. The noise occurs when accelerating from stops, driving over bumps, or even when weight sits in the rear seat or trunk while parked. Owners describe hearing metal rubbing against metal. GM issued a service bulletin directing dealers to add a washer to the rear shock tops and replace rear suspension knuckles; the root cause is the shock absorber housing making contact with the strut mount when the washer is missing or improperly installed. Rear knuckles are on national back order, delaying repairs by months. Several owners had rear shocks replaced without stopping the noise—a temporary fix that doesn't address the knuckle failure underneath.
Beyond suspension, owners report dangerous electrical and drivetrain gremlins: vehicles entering limp mode (engine power reduced to 20–30 mph) unpredictably on highways, complete stalling at red lights with loss of all electrical power, brake failure during highway driving, and shifter position sensing failures that prevent the car from recognizing Park. Door locks have trapped occupants. A dealer software update and battery replacement failed to cure recurring issues. One engine mount collapsed, pulling the right front axle out of alignment. Most repair attempts—whether at the dealer level or through manufacturer contact—have left owners' safety concerns unresolved.
Same Chevrolet Malibu suspension reports on nearby years: 2013 · 2018
Failure modes owners describe
Rear suspension popping/thumping noise
Metallic popping or thumping noise from the rear suspension occurring when driving over bumps, accelerating from stops, or when weight is placed in the rear or trunk. Owners report the noise happens at low speeds or even when parked if someone pushes down on the trunk. Multiple owners had rear shocks replaced without resolving the issue.
When: 28,000–96,990 miles; occurs at low speeds and over bumps
Symptoms owners cite: Metallic popping noise from rear; Thumping sound when accelerating from stops; Noise when weight placed in rear seat or trunk; Creeping/thumping sound over uneven roads or driveways
Repairs/costs cited: GM issued service bulletin recommending adding washer to top of both rear shocks and replacing rear suspension knuckles. Rear shock absorber outer housing making contact with shock mount. Rear knuckles reported on national back order (~6 months delay). One owner had both rear shocks replaced with no improvement; another had washer added at dealer with no resolution.
Recalls/TSBs owners mention: GM service bulletin issued recommending washer addition and rear suspension knuckle replacement. Dealerships performing repairs; some owners report runaround and diagnostic fees with no fix achieved.
Rear suspension structural failure
Top of rear shock making physical contact with bottom of strut mount due to missing or improperly installed washer, causing suspension knuckle failure and bushing degradation. Owners and dealers identified the need for rear suspension knuckle replacement.
When: 41,000–96,990 miles
Symptoms owners cite: Metal rubbing against metal sound; Suspension knuckle failure risk; Bushing failure
Repairs/costs cited: Rear shock outer housing contacting shock. Rear suspension knuckles require replacement; parts on national back order causing 6-month repair delays. Without washers, shock-to-strut-mount contact cascades to knuckle and bushing failure.
Recalls/TSBs owners mention: Service bulletin issued; rear knuckles on back order nationally.
Engine power reduced derate (limp mode)
Vehicle intermittently enters reduced-power mode, limiting speed to 20–30 mph with warning lights (engine power reduced, traction control, check engine) displayed simultaneously. Incidents occurred on highway and city driving. Computer update provided at dealer did not resolve issue; one owner had to pull off road to restart vehicle.
When: Occurs randomly; reported at 64,763 miles
Symptoms owners cite: Engine power reduced warning displayed; Speed limited to 20–30 mph; Traction light on; Check engine light on; Loss of acceleration on highway
Codes mentioned: Engine power reduced, Traction control activated
Repairs/costs cited: One owner paid $100 diagnostic fee; dealer recommended computer update, which did not resolve recurring issue. No further repair attempts documented.
Recalls/TSBs owners mention: Dealer performed computer software update with no lasting fix.
Vehicle stalling at stops with battery save mode
Vehicle completely shut down at traffic lights and during braking, triggering battery save mode warning and StabiliTrak light. All electrical systems lost power (windows, radio, climate control non-functional). Vehicle restarted after 5+ minutes with no permanent electrical fix found.
When: December 2020; 64,763 miles
Symptoms owners cite: Complete engine shutdown at red lights; Battery save mode warning; StabiliTrak light illuminated; Loss of all electrical systems; No acceleration until restart
Codes mentioned: Battery save mode, StabiliTrak
Repairs/costs cited: Vehicle serviced but no mechanical cause identified. Liquid-passing-through sound noted at stops after initial incidents.
Recalls/TSBs owners mention: Dealer service unable to diagnose or fix issue.
Shifter position sensing failure (shift-to-park issue)
Vehicle fails to recognize Park position even when shifter is in Park, preventing engine shutdown and leaving power systems active. Owner must jiggle shifter multiple times to register Park. Shifter was previously replaced and recurrence of the same malfunction reported.
When: Occurs intermittently; second occurrence after prior repair
Symptoms owners cite: Vehicle does not recognize Park position; Engine does not turn off completely; Power systems remain on; 'Shift to park' message displays despite being in Park; Shifter must be jiggled to register Park
Codes mentioned: Shift to park
Repairs/costs cited: Shifter was previously replaced; same failure returned. Dealership replaced parts again without resolving issue.
Recalls/TSBs owners mention: Dealer performed shifter replacement; codes verified at dealership.
Brake system performance degradation
Vehicle exhibited reduced or inconsistent brake responsiveness. One owner experienced complete brake failure during highway evasive maneuver, forcing off-road impact to stop vehicle. After repair, brake application at stops sometimes produces no movement, nearly causing traffic incidents.
When: Highway incident; intermittent at stops
Symptoms owners cite: Complete loss of braking on highway; No vehicle movement when pedal pressed at stops; Brakes checked good but performance still degraded; Grinding and stuttering noise when braking at slow speeds
Repairs/costs cited: Brakes inspected and deemed 'good' despite failure. No repair documented.
Recalls/TSBs owners mention: Dealer inspection only; no repair actions taken.
Electrical/drivetrain intermittent failures with StabiliTrak and ABS warnings
Vehicle shook, decelerated, and exhibited battery failure. Door locks became inoperable, trapping occupant inside. Battery replaced and coil spring replaced without resolving failures. Additional incidents of StabiliTrak/ABS warning lights with grinding and stuttering during braking at slow speeds and in reverse.
When: 62,000 miles; intermittent recurrence
Symptoms owners cite: Vehicle shaking and deceleration; Battery failure; Door locks inoperable; StabiliTrak light on; ABS light on; Braking grind and stutter at low speeds and in reverse
Codes mentioned: StabiliTrak, ABS
Repairs/costs cited: Battery replaced; coil spring replaced. Failures continued.
Recalls/TSBs owners mention: Manufacturer contacted but unable to assist. Vehicle not repaired.
Engine mount collapse
Right engine mount collapsed, resulting in humming noise from headliner module and engine. Right front axle also required replacement. Indicates possible cascade failure from engine movement.
When: Mileage not specified
Symptoms owners cite: Humming noise from headliner module; Humming noise from engine bay; Right front axle failure
Repairs/costs cited: Right front axle needed replacement; engine mount collapsed.
Recalls/TSBs owners mention: Unknown; owner sought reimbursement and repairs.
Synthesized from 18 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had suspension 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 suspension problem on the 2016 Chevrolet Malibu?
It's a meaningful issue. 18 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $900.
At what mileage does the suspension typically fail?
Across the 12 complaints that reported odometer mileage, most suspension failures cluster between 60,000 and 85,000 miles, with the median around 67,335. A quarter of owners report trouble before 60,000; a quarter make it past 85,000. 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 $900 for suspension 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 suspension?
No active recalls currently cover suspension 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.