Just a warning to everyone here. I have a 2004 Malibu and my daytime running light/turn signal burnt out. When I went to replace it I found that the cause of the bulb failure was hot molten plastic had dripped down onto the hot bulb and burnt. I thought that the bulb must have been defective, but when I checked the other side I had the same problem happening.

The bulb is to hot for the Lamp assembly that GM has designed. The bulb gets so hot that the orange plastic lens around the bulb becomes soft and molted and starts to burn away. When it gets hot enough it will drip down onto the hot bulb and may catch fire. I was lucky. Although I do believe from the remains of the bulb and the lens that a small fire did occur it did not spread as the bulb burned out before it could.

I took my car to the dealer and they said to contact GM. While I was at the dealer I went to the used car lot and checked out 5 other Malibu's from 2004 to 2006 and they all had the same thing happening. But a various stages.

Gm called me yesterday and said they will look into it and get back to me. But in the meantime please check your Malibu's for this problem. This is a major design flaw and a fire hazard that could cost someone very dearly if it is not fixed. I will let you know if when I hear back from GM.

Btw I have also reported this to Transport Canada Safety Division.


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I've had my '04 for a year now...I think I've only changed each signal once. No sign of melting or warping plastic insofar that I can tell (and it should be obvious), but thanks for the warning.

 

Just had the right turn parking light go out, bulb connector was burned, connection in socket was burned and melted a bit.
Scraped the connection on both the bulb and socket to get it going, bought new bulbs and now shopping for new after market socket, should be cheaper than GM.

 

Had to order the socket from GM, seems to be GM exclusive. Must be the DRL through the BCM. The socket is 4 wire, 2 power, 2 ground.

 

Well I have now heard back from GM and they have refused to do anything about this issue citing age and milaege on the vehicle. Transport Canada doesnt seem interested either. I have found several complaints at the nthsa's site and will post them in a new reply. I have been checking out every Malibu I see and the vast majority of them seem to have this same problem. Guess it will take a real fire and someone getting hurt before anyone will listen. Anyone have any ideas on how to pursue this matter further?

 

why waste your time and energy? If it was a real problem, and people were accually geting hurt or fires being started, there would be a bulletin out already

 

Because of the principal of the matter sir. When I bought my car (new) I expected to be given a safe and proven car. Now a design flaw is causing a potential safety hazard and GM wants to ignore it. Whether or not a serious fire has started as of yet the potential is there.

 

This melting/burning/smoking of the lens has affected the appearance of the outside of the hl assembly as well.