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2005 Saturn Relay Recalls, Issues & Maintenance

The 2005 Saturn Relay carries 3 open NHTSA recalls — most recently covering mid/rear assembly and steering. No recurring owner-reported issue clusters are on file. GM wound Saturn down in 2009, so parts now come through the GM catalog rather than a Saturn dealer. Which Saturn you own changes the maintenance picture completely. The S-series cars, meaning the SL, SC, and SW, use a 1.9 liter four with a timing chain, and the twin-cam version is known to burn oil as it ages, so checking the dipstick between changes matters more than the interval does. The L-series and Astra are Opel designs and want European-spec parts. The later Vue, Ion, Aura, Outlook, and Sky are mainstream GM under the badge. One item deserves a direct warning: 2002 to 2005 Vue models fitted with the VTi continuously variable transmission had a poor reliability record, and GM stopped building it. If you are buying one, confirm which transmission it has first.

3 Open Recalls

Source: NHTSA

SEATS:MID/REAR ASSEMBLY

Campaign #05V061000 · Feb 18, 2005

Issue: ON CERTAIN MINIVANS, THE OUTBOARD RELEASE HANDLE ON THE IMPACT-SIDE SECOND-ROW BUCKET SEAT MAY BE ACTUATED AND THE REAR LATCHES MAY UNLATCH EARLY IN A SIDE IMPACT CRASH. THIS WAS DISCOVERED IN A SIDE IMPACT TEST RUN BY GM, UNDER CONDITIONS SIMILAR TO NHTSA'S NEW CAR ASSESSMENT PROGRAM (NCAP) SIDE IMPACT TEST.

Risk: IF THE REAR LATCHES OF THE SEAT RELEASE EARLY IN A SEVERE SIDE IMPACT, THE FRONT OUTBOARD LATCH MAY DISENGAGE AND INCREASE THE POTENTIAL FOR INJURY TO THE OCCUPANT OF THE SEAT.

Fix: DEALERS WILL REMOVE THE SEAT LATCH RELEASE HANDLE AND INSTALL A BLACK PLASTIC CAP OVER THE EXPOSED METAL STUD TO ELIMINATE THE SIDE IMPACT SAFETY CONCERN FREE OF CHARGE. THE RECALL BEGAN ON APRIL 5, 2005. OWNERS MAY CONTACT SATURN AT 1-800-972-8876, CHEVROLET AT 1-800-630-2438, AND PONTIAC AT 1-800-620-7668.

STEERING

Campaign #09E005000 · Feb 17, 2009

Issue: DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.

Risk: A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARNING.

Fix: DORMAN WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE STEERING KNUCKLES FREE OF CHARGE AND REIMBURSE THE REPAIR FACILITY OR OWNER FOR LABOR. THE RECALL BEGAN ON FEBRUARY 23, 2009. OWNERS MAY CONTACT DORMAN'S TOLL-FREE HOTLINE AT 1-800-523-2492 AND PRESS 5.

PARKING BRAKE

Campaign #05V287000 · Jun 20, 2005

Issue: CERTAIN SPORT UTILITY VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, 'PASSENGER CAR BRAKE SYSTEMS.' TO MEET THE STANDARD, THE VEHICLE MUST NOT MOVE FOR FIVE MINUTES WHEN STOPPED ON A STEEP HILL WITH THE PARKING BRAKE APPLIED AND THE VEHICLE IN NEUTRAL (N). SOME OF THESE VEHICLES FAILED THIS TEST.

Risk: WHEN THE PARKING BRAKE IS RELEASED, THE DRIVER MAY NOTICE UNINTENDED BRAKING WHEN ACCELERATING, DECELERATING, OR COASTING, AND A NOISE COMING FROM THE REAR OF THE VEHICLE. UNINTENDED VEHICLE MOVEMENT COULD OCCUR INCREASING THE RISK OF A CRASH.

Fix: DEALERS WILL INSPECT FOR PARKING BRAKE LEVER SLIPPAGE AT EACH REAR BRAKE CALIPER AND REPLACE THE CALIPER IF LEVER SLIPPAGE IS IDENTIFIED. THE RECALL BEGAN ON NOVEMBER 14, 2005. OWNERS MAY CONTACT BUICK AT 1-866-608-8080, CHEVROLET AT 1-800-630-2438, PONTIAC AT 1-800-620-7668, OR SATURN AT 1-800-972-8876.

Recall data refreshed Jul 9, 2026.

Known issues for this vehicle

What drivers and federal regulators have officially reported about the 2005 Saturn Relay.

Reported to NHTSA

NHTSA has 91 complaints on file for the 2005 Saturn Relay (2005-03 → 2018-07). We haven't grouped them yet for this specific vehicle — for now, the full list lives on NHTSA.

Top reported components: SERVICE BRAKES (40) · HYDRAULIC (26) · ELECTRICAL SYSTEM (24)

Read all complaints on NHTSA →

Note: NHTSA also opened 3 defect investigation(s) on this vehicle that closed without action.

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 18, 2026. Investigation data refreshed Sep 1, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 5,000 mi

Models from about 2003 on use the GM Oil Life System. Change when it asks and at least once a year. On S-series cars with the twin-cam 1.9, check the level every other fuel stop. Oil consumption on a worn one can empty the sump well before the next service is due.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 7,500 mi

Rotate every 7,500 miles. Check the sidewall date codes too. On cars this age, tires usually time out before they wear out.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 7,500 mi

Inspect pads, rotors, hoses, and hard lines at every service. Rear drums on S-series cars and rear calipers on the Vue and Ion both stick on vehicles that sit for long stretches.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 24,000 mi

Replace every 2 years. This is the single cheapest thing you can do to keep an aging ABS pump and calipers alive.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Automatic Transmission Fluid

Every 45,000 mi

Drain and fill every 45,000 miles. Fluid depends on the car: Dexron VI for most conventional automatics, a specific CVT fluid for 2002 to 2005 Vue models with the VTi, and Saturn-spec manual gear oil for the S-series manuals. Confirm the spec before anyone pours anything in.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Spark Plugs

Every 100,000 mi

100,000 miles on platinum or iridium plugs. On the S-series 1.9 and the Ecotec fours, replace the coil pack boots at the same time. Brittle boots misfire and mimic a failing coil.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Serpentine Belt & Tensioner

Every 60,000 mi

Replace the belt and the tensioner as a set once either one is cracked, glazed, or noisy. A tired tensioner will destroy a new belt.

Estimated cost — typical U.S. ranges

Dealer

~$195–$235

Shop

~$135–$165

DIY

~$20–$50

DIY-friendly if you can reach the tensioner. Inspect for cracks rather than swap on a strict mileage interval.

Engine Air Filter

Every 30,000 mi

Replace every 30,000 miles. Easy access on the S-series and the Ecotec engines.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Coolant Replacement

Every 100,000 mi

Every 5 years on a car this old. Most Saturns use orange Dex-Cool, which must never be mixed with green coolant. Ask the shop to check for seepage at the water pump and the intake gasket while the system is open.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Power Steering Check

Every 50,000 mi

Most of the lineup uses conventional hydraulic steering, so check the fluid level and the hoses. The Ion and some Vue models use an electric power steering unit instead, which has no fluid but was the subject of GM recall activity. Worth confirming yours was addressed.

Estimated cost — typical U.S. ranges

Dealer

~$185–$220

Shop

~$130–$155

DIY

~$15–$40

Most cars built after ~2012 use electric power steering and have no fluid to service.

Battery & Charging System Test

Every 25,000 mi

Test the battery and alternator once a year. A weak battery on this generation of GM electronics produces warning lights that look like much more expensive problems.

Estimated cost — typical U.S. ranges

Dealer

~$225–$390

Shop

~$160–$280

DIY

~$130–$250

Most auto-parts stores test and install batteries free with purchase. Skip the dealer markup.

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2005 Saturn Relay reflects Saturn's published service intervals and the GM Oil Life System system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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