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 ↗2020 Chevrolet Malibu brakes problems
severe Owners of the 2020 Chevrolet Malibu have filed 26 NHTSA complaints about the brakes, typically surfacing around 75,000 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
26
Recalls
0
Avg fix
$450
| Model year | brakes complaints |
|---|---|
| 2016 Malibu | 54 |
| 2017 Malibu | 40 |
| 2018 Malibu | 40 |
| 2019 Malibu | 15 |
| 2020 Malibu (this page) | 26 |
3crashes
3injuries
When does it fail?
Of the 26 brakes complaints filed for the 2020 Chevrolet Malibu, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 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
Owners have filed 26 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 service bulletin provides information about GM Accessories - Dealer-Installed, Repaired or Replaced During Warranty Coverage Period.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2020 Chevrolet Malibu report brake vacuum pump failures causing loss of braking power and hard brake pedals across a wide mileage range, starting as early as 40,000 miles. The pump failure typically presents with a stiff or hard-to-depress brake pedal and diminished stopping power. Many owners describe sudden onset with no prior warning; a check engine light is often the first indicator. The failure sometimes occurs at highway speeds, creating dangerous situations.
Owners report a documented pattern: when the vacuum pump fails, secondary damage cascades. The pump failure is linked to camshaft reluctor wheel misalignment or damage, which can lead to engine damage severe enough to require full engine replacement in some cases. Repair estimates range from $3,000 to $12,000+. One owner reports replacing the pump four times.
Multiple owners note an "Engine Reduced Power" message or reduced power mode during failure. Some experience associated oil loss and brake fluid leaks. One owner reports the issue correlates with low oil level, with symptoms easing after an oil change. A TSB is confirmed as issued by Chevrolet; owners also reference a prior recall covering model years 2017–2019 for the same problem, raising questions about why a recall was not extended to the 2020 model year. Incidents have resulted in collisions, with airbag systems not deploying in some crashes.
Same Chevrolet Malibu brakes reports on nearby years: 2017 · 2018 · 2019
Failure modes owners describe
Brake vacuum pump failure
The brake vacuum pump fails suddenly, eliminating vacuum pressure needed for power braking. Loss of vacuum causes the brake booster to stop functioning, requiring extreme pedal pressure to stop the vehicle or making stopping impossible.
When: 40,000–118,000 miles; multiple reports in 55,000–90,000 range
Symptoms owners cite: Sudden complete loss of braking power or severe reduction in stopping ability; Brake pedal becomes extremely stiff and hard to depress; Brake pedal may travel to floorboard with no resistance; Check engine light illuminates at or near time of failure; 'Engine Reduced Power' message displayed; Failure occurs without prior warning signs in most cases; ABS warning light or traction control light may illuminate
Codes mentioned: P0556, ABS fault codes (intermittent), Brake pressure sensor error/defective code
Repairs/costs cited: Vacuum pump replacement required; costs $800–$3,000+ depending on scope. One owner replaced pump four times.
Recalls/TSBs owners mention: TSB issued by Chevrolet for 2020 model year; recall covered 2017–2019 model years for same defect but not extended to 2020; GM advised towing to dealer for diagnostic tests in at least one case
Secondary camshaft and engine damage from pump failure
When the vacuum pump fails, owners report the camshaft reluctor wheel becomes misaligned, twists, or sustains damage. This secondary failure cascades into severe engine damage, sometimes requiring full engine replacement.
When: Occurs during or immediately after vacuum pump failure; noted at 55,000–106,000 miles
Symptoms owners cite: Camshaft reluctor wheel in improper position or twisted; Engine stalling during or shortly after brake failure event; Severe engine performance loss requiring replacement; Metal fragments reported from failed pump entering engine
Codes mentioned: Camshaft position errors (implied by reluctor misalignment)
Repairs/costs cited: Full engine replacement or major engine rebuild quoted at $10,000–$12,000+. One owner received $10,000 estimate (later corrected to $11,000). Dealers refuse or delay repairs pending GM direction.
Recalls/TSBs owners mention: Manufacturer advised customer to return to original dealer for additional diagnostics; some owners report manufacturer contacted for assistance but no resolution provided
Brake vacuum pump failure recurring after replacement
In at least two documented cases, the vacuum pump was replaced but the failure recurred within a short period, suggesting either a defective replacement part, underlying design flaw, or related system issue not addressed by pump replacement alone.
When: Within days to weeks after initial pump replacement
Symptoms owners cite: Identical brake failure symptoms return after pump replacement; 'Engine Reduced Power' message reappears; Unintended deceleration while driving at highway speed (80 MPH reported)
Repairs/costs cited: First dealer refused to re-repair; customer directed to original dealer for additional diagnostics. Vehicle not repaired.
Recalls/TSBs owners mention: Manufacturer notified and advised customer to return to first dealer; no resolution documented
Hard brake pedal and reduced braking associated with low oil level
One owner reports a pattern where brake symptoms correlate with oil level; as oil drops near change interval, brake pedal resistance increases and brakes feel different. Owner describes a grinding sensation at ~40% oil depletion but notes no oil change warning light activates.
When: Occurs during normal operation as oil depletes between service intervals
Symptoms owners cite: Brake pedal becomes harder to depress as oil level drops; Subtle grinding sensation from brakes; Symptoms fully resolve after oil change; No oil change warning light activates despite low oil
Repairs/costs cited: Brake power booster replaced once; owner now monitors oil level closely and performs frequent checks. Mechanics unfamiliar with this root cause.
Synthesized from 26 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
Vehicle vacuum pump failed I have changed it 4 times now. Saw there have been more cases
The contact owns a 2020 Chevrolet Malibu. The contact stated that while driving approximately 45 MPH and approaching a stop light the braking system malfunctioned when pressing the brake pedal causing the vehicle to crash into the rear of a second vehicle. The contact indicated that the vehicle did not reduce speed when pressing the brake pedal and the collision avoidance feature did not…
I am writing to formally report a critical safety issue with my 2020 Chevrolet Malibu, which resulted in a severe accident and posed significant risks to my safety and the safety of The issue involves the brake vacuum pump, which failed while I was driving. The component is currently with the vehicle, which is stored in a parking facility, and is available for inspection upon request. The…
The contact owns a 2020 Chevrolet Malibu E2. The contact stated that while at a complete stop at the stop sign, the auto START/STOP mode engaged, however the vehicle failed to restart upon releasing the brake pedal. The message "Engine Reduced Power" was displayed. The contact stated that the vehicle failed to restart after several attempts. The vehicle was towed to the dealer where it was…
The contact owns a 2020 Chevrolet Malibu. The contact stated while driving 35 MPH and depressing the brake pedal to slow the vehicle, the vehicle stalled. The contact stated that the oil change service light was illuminated. The vehicle was not drivable. The contact towed the vehicle to the local dealer, where it was diagnosed with needing the vacuum pump and engine to be replaced. The vehicle…
Had brakes trouble with your 2020 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 2020 Chevrolet Malibu?
It's a meaningful issue. 26 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 9 complaints that reported odometer mileage, most brakes failures cluster between 57,000 and 90,000 miles, with the median around 75,000. A quarter of owners report trouble before 57,000; a quarter make it past 90,000. 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/2020/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.