Now I would have hoped that GM would have taken this more seriously but all my dealer told me to do was call them. I called them and they didnt even bother to look at the car to see the damage before they said that they wouldnt cover it. Now it says here you are a GM tech. Have you looked at any malibu's to see the problem?

And if you take a look at the nthsa's website you will see other reports of this as well

 

Sorry for having to draw it out in seperate posts but this forum is not letting me post it all at once.

 

I also have this problem with my 2005 Malibu. Went to my dealership to find out if there is a different bulb that i could use. No help!

 

How many miles are on the vehicles when this was notice...

 

The problem is mostly in high temp climates, 35 K on mine in the rust belt , no problem.

 

Less than 50000 on mine and i live in the midwest.

 

Must get hot in the mid west, we had one 90 deg day so far this summmer.

 

why don't you light fire to the car, blame it on the headlight assy, and sue the pants off of GM. Maybe someone will listen to you then

 

don't be so hard on the guy. he's right. these headlamp assemblies fail prematurely. both of mine on an '04 maxx need replacement. i'm at 80 000 km (50 000 mi). the amber lamp shroud overheats, melts, drips onto the lamp connector and shorts it out. replacing the bulb doesn't fix it, and it leaves a burnt area around the amber lamp.

only fix is to replace the whole headlamp unit, or the connector and shroud if you could piece that together. but then it's just a matter of time until it does it again. the critical difference betweenmine and the original poster'scases, and most other readers here, is that our cars have canadian drl's, which work off the high-intensity side marker bulbs. not sure if it's the same for you guys, but judging from the one headlamp assembly i ebay'd up from the states, i don't think you guys are running front side markers drl's. i think chevy didn't properly engineer it for canadian duty cycles.

fire hazzard warning may be extreme, but inoperable turn signals is not a good thing either.

anyway, anybody got a fix? other than replacing the unit every couple of years?

 

I checked mine when I had bulb connection problems. The DRL on my US car is using the parking lamp, I was surprised, I thought it was the turn lamp. No melting just the bulb connection high resistance.