Chevrolet Cobalt Structure Problems

Source: NHTSA · Updated Aug 15, 2026 · 155 complaints analyzed

Owners have filed 155 complaints with NHTSA about structure problems on the Chevrolet Cobalt across 6 model years. The 2006 model year has the most (51). The words owners use most often: “side door” (18% of reports).

What owners describe

Phrases that appear unusually often in these complaints compared with complaints about other cars.

  • Side door: mentioned in 28 of 155 complaints (18%)
  • Inside outside: mentioned in 15 of 155 complaints (10%)
  • Ignition switch: mentioned in 9 of 155 complaints (6%)
  • Lost control: mentioned in 8 of 155 complaints (5%)

At what mileage do structure problems happen?

Based on 130 complaints that reported the odometer reading.

Under 10k miles17 · 13%
10k–25k miles9 · 7%
25k–50k miles23 · 18%
50k–75k miles26 · 20%
75k–100k miles20 · 15%
100k–150k miles24 · 18%
150k+ miles11 · 8%

How serious are the reports?

Of 155 complaints, 33 mention a crash, 1 a fire, 24 an injury.

Chevrolet Cobalt structure complaints by model year

Peak: 2006, with 51 complaints
2005: 462005462006: 512006512007: 192007192008: 112008112009: 152009152010: 13201013

n = 155 complaints · Source: NHTSA

Model yearStructure complaintsShare of that yearMedian miles
2010 Cobalt132%63,002
2009 Cobalt152%50,343
2008 Cobalt111%80,390
2007 Cobalt191%54,000
2006 Cobalt512%60,000
2005 Cobalt463%70,000

When owners reported it

Peak: 2014, with 33 complaints
2005: 3200532006: 662007: 9200792008: 222009: 4200942010: 18182011: 152011152012: 662013: 172013172014: 33332015: 152015152016: 552017: 8201782018: 662019: 3201932020: 112021: 3202132024: 11

n = 155 complaints · Source: NHTSA

Related recalls (1)

StructureJan 18, 2007 · NHTSA campaign 07V014000 · 98,707 vehicles

Model years: 2005, 2006

Problem: Certain passenger vehicles not equipped with optional roof-mounted side impact air bags fail to comply with the requirements of federal motor vehicle safety standard no. 201, 'occupant protection in interior impact.'

Risk: In a crash, head impact protection may be inadequate.

Fix: Dealers will install energy absorbing plastic to the headliner trim to reduce the severity of head impacts in a crash. The recall began on march 21, 2007. Owners may contact chevrolet at 1-800-630-2438.

What owners report

Short excerpts of recent complaints, with personal details removed. Full reports are on NHTSA.gov.

Internal mechanism of the driver-side door handle broke and the door would not open from the inside. Tne dealership confirmed that the inside door ah glue is broken. The cable retainer snapped apart and the cable cannot stay connected. This might be available for inspection. Driver must exit the…

Received Oct 25, 2024 · NHTSA complaint 11621929

My headlight an blinker quit working new bulbs an all new wiring it it still will not work My trunk button also just stopped working an the fuse is not blown. I even replaced it just to make sure still nothing. Door panel clips won’t stay in bought new ones same thing so now my handle is coming…

Received Oct 28, 2021 · NHTSA complaint 11438524

The contact owns a 2007 Chevrolet Cobalt. The contact stated that while his son was driving at an undisclosed speed, the steering warning light illuminated. Additionally, the pipes connected to the manifold were rusted and had detached. The contact called the local dealer however, the vehicle was…

Received Jul 27, 2021 · NHTSA complaint 11426660

The contact owns a 2006 Chevrolet Cobalt. The contact stated that after turning off the vehicle, there was an abnormal fuel odor coming from the vehicle. Upon inspection, the contact discovered severe corrosion on the rear driver’s side undercarriage of the vehicle. Due to the rust, the fuel…

Received Jun 14, 2021 · NHTSA complaint 11420860

The steering wheel keeps locking. There are times that i get stranded and have to have someone pick me up because o cannot get the steering wheel to unlock.this has been going on for about as long as i owned the car. This happens when car is in stationary position. The paint of the car is peeling i…

Received Jun 10, 2020 · NHTSA complaint 11328104
Chevrolet Cobalt
2005-2007 Chevrolet Cobalt photographed in USA.. Representative photo; appearance varies by model year. Photo: IFCAR, Public domain, via Wikimedia Commons.

Frequently asked questions

Do all Chevrolet Cobalts have structure problems?

No. NHTSA has 155 owner complaints about structure for the Chevrolet Cobalt. Complaint data shows that the problem is reported, not how many of all cars sold are affected.

Was there a recall on the Chevrolet Cobalt structure?

Yes: 1 safety recall list structure. Check your VIN on NHTSA.gov to see whether the fix was done on your car.

What do owners say about structure problems on the Chevrolet Cobalt?

The most frequent phrase is “side door”, in 28 of 155 complaints, followed by “inside outside” (15).

Other Chevrolet Cobalt problems

See all Chevrolet Cobalt problems.