Sorry, checked it wrong. I started the engine and put it in neutral, DRL was using the turn bulb, turned on parking lights and the DRL went off and parking bulb lighted.

 

I wish it would burn up. Well least they go in unison I know have to replace the left dtr/signal. It was melting when I noticed the right one and I just left it and hoped it would burn. And ask anyone that knows anything about fires or has half a brain in there head that hot molten plastic dripping onto a hot bulb is definately a fire hazard. And I do not live in a hot climate. Hell Im a Canadian and live in Toronto.

Could anyone here suggest a good media contact in the Toronto area?

 

I would run the parking lights during the summer months if I had your problems. Seems strange, I am in Maine and your in Toronto and I have no sign of melting.
We over here have the option of turning off the DRL per start up, I know Canada won't let you do that.

 

all right, leadfoot. don't take it personally. i was trying to be on your side.

good luck with the media ranting, but i think most would agree that you're overreacting. bad design? yes. potentially life-threatening situation? not really. unless they spec'd the plastic to be highly explosive.

anyway, i just ebay'd a right-side headlamp assembly up from the states. it seems like you do have the same issue after all. there's perforation in the plastic that shows that the process is starting.

newly installed ebay'd left side headlamp assembly stilllike newafter 3 weeks in my car.

i'm gonna take a more low-key approach and talk to the local dealership about coming up with a fix.

 

ok, here's what i got; "legal precedence" :

http://www.s2ki.com/forums/index.php...=152582&st=100

from our friends with s2000's with pink tail lamps. they had to hassle the nhtsa, which in turn hassled honda, which finally caved and did a model year 2000 recall. let's report something similar and hope for the same result:

https://www-odi.nhtsa.dot.gov/ivoq/

unfortunately, this is an american organization, so i'm out of the picture. i'll keep digging for a canadian equivalent, but by all means, do your part on your side of the border, and i'll keep digging for a canadian equivalent, and our complaint efforts combined will hopefully end up with free upgraded headlamp assemblies for everyone.

 

My '04 Maxx (100,000 miles) just developed the same issue; driver side parking lamp plastic base melted, socket was burnt. Replaced lamp, two weeks later the new lamp went out, plastic base fused with base of glass. Both driver and passenger side amber plastic lamp housing has been partially melted at the top.

Anyone have success in talking with Chevy dealer about this?

I did file NHTSA complaint.

 

Found this on the NHTSA web site:

NHTSA Action Number : EA09004
NHTSA Recall Campaign Number : N/A
Make / Models : Model/Build Years:
CHEVROLET / MALIBU 2004-2005

CHEVROLET / MALIBU MAXX 2004-2005

Manufacturer : GENERAL MOTORS CORP.
Component :
EXTERIOR LIGHTING:BRAKE LIGHTS
EXTERIOR LIGHTING:HEADLIGHTS
EXTERIOR LIGHTING:TAIL LIGHTS
EXTERIOR LIGHTING:TURN SIGNAL

Date Investigation Opened : March 20, 2009
Date Investigation Closed : Open
Summary:
THE SUBJECT VEHICLES MAY EXPERIENCE LOSS OF FUNCTION OF ONE OR MORE OF THE PARK, TURN, STOP OR DRL LAMPS. FAILURE OF THE BULB MAY ALSO INCLUDE DISCOLORATION (HEAT DAMAGE) TO THE BULB SOCKET. GENERAL MOTORS (GM) TECHNICAL SERVICE BULLETIN (TSB) NUMBER 06-08-42-004C INSTRUCTS TECHNICIANS TO EXAMINE THE LAMP HOUSING FOR SIGNS OF DISCOLORATION AND TO REPLACE THE BULBS AND OR SOCKETS DEPENDING ON THE SEVERITY OF THE DISCOLORATION AND THE CONDITION OF THE BULBS AND SOCKETS. THE SCOPE OF INVESTIGATION IN THE PRELIMINARY EVALUATION (PE08-062) WAS THE 2004 MALIBU/MAXX. HOWEVER, THE AGENCY EVALUATED GM'S WARRANTY DATA WHICH INDICATES THAT THE 2005 MODEL YEAR (MY) MALIBU AND MALIBU MAXX VEHICLES ARE ALSO AFFECTED BY THIS CONDITION. THIS EA COVERS BOTH MODEL YEARS. GM REPORTS DESIGN AND PRODUCTION IMPROVEMENT CHANGES FOR MODEL YEAR 2006 MALIBU AND MALIBU MAXX VEHICLES.

 

I had this same problem, I changed both of the bulb housing - there is a service bulletin that the dealer can print out for you, but it is honestly a 20 min fix. no need to buy the wiring harness they will try to sell you for $200+ per side, just get the new bulb housings ($10-$15) per side. You will have to cut the old ones off, splice the new ones one - we butted them together and good to go...have not have to change my monthly bulbs since. - oh and I am a girl...lol - 2005 malibu maxx

 

I noticed this problem years ago and approached the dealer about my 2005 discolored on the top of the unit and the DRL amber globes melted. Chevrolet paid for the new parts (entire housings) and I paid for the labor. Now, years later, the amber globes are brittle again.

 

Here's a copy of GENERAL MOTORS TSB 06-08-42-004C: