NHTSA Complaint #746537 — 2001 CHEVROLET MALIBU

ENGINE PISTONS REPLACED AT 2395 MILES DUE TO" PISTON SLAP". REPLACED ALL SIX PISTONS WITH TEFLON COATED ONES. PATCH AREAS ON OPPOSITE SIDES OF PISTON IN AREA WHERE THE MOST VIBRATION AND WEAR OCCURS. ALL SIX PISTONS SHOWED SIGNS OF SIGNIFICANT WEAR IN AREAS WHERE TEFLON ADDED. ADVISED BY DIFFERENT DEALER ASE CERTIFIED MECHANICS & SERVICE MANAGER THAT INSTALLING TEFLON COATED PISTONS IS JUST A SHORT-TERM STOP-GAP MEASURE AND THE PROBLEM WOULD RETURN. PHOTOS WERE TAKEN OF OLD PISTONS. BRAKES CONTINUE TO MAKE POPPING NOISE, LIKE CALIPERS ARE STICKING AND THERE IS NOTICABLE REDUCED BRAKING ON WET SURFACES. DEALER SAYS "NOTHING IS WRONG". RACK AND PINION FAILED INITIALLY AT 4044 MILES . REPLACED AND THE SAME SOUNDS AND FEEL HAS RETURNED. 24 DAYS OUT-OF-SERVICE TO DATE. WILL TAKE ACTION VIA LEMON LAW AFTER 6 MORE DAYS OUT-OF-SERVICE.*AK