2004 Chevrolet Malibu Headlight Problems

Which parts fail

• Turn signal
  13
• Headlights
  6
• Turn signal › Switch
  2
• Brake lights
  2
• Headlights › Concealment devices
  2
• Tail lights › Switch
  1

Components named in complaints (headlights, tail lights, turn signals, interior lights).

Mileage when the problem started

• Under 25k
  913%
• 25k–50k
  1319%
• 50k–75k
  1421%
• 75k–100k
  1421%
• 100k–150k
  1015%
• 150k+
  710%

Owner reports

Selected complaints filed with NHTSA by 2004 Chevrolet Malibu owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2004 Chevrolet Malibu. The contact stated while the vehicle was parked and the engine running the contact noticed that their front driver and passenger headlight were very low in both low beam and high beam and that the light eventually burned out. The contact inspected the vehicle and saw that the light bulb sockets for both the front driver side and passenger had melted. The contact stated the cause of the failure is the wiring behind the headlight assembly that is causing the headlight socket to melt. The contact replaced the headlight bulb sockets themselves with aftermarket parts to repair the failure, however, the failure persisted and reoccurred. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was unknown.

I was driving to work with my son and sister in the car when the steering wheel suddenly got very tight and started jerking when I attempted to make a left or right turn. I then stopped at a gas station and as soon as I came to a complete stop the vehicle shut off before I could turn it off manually. I then attempted to turn the key on and start the vehicle but it would not turn over, it would only make a clicking sound. I called a friend that was close by to come and assist me so when they arrived I asked them to jump my vehicle off via jumper cables which did get my vehicle's engine to finally start. The car sounded very weak as if it was going to shut off again once we disconnected the jumper cables but it didn't shut off. Nothing was working inside the car or outside meaning I had no radio, no interior lights and nothing on my dash was working. …

First, the car routinely burns out turn signals, and overheats the turn signal to the point that it melts the housing thta the light bulb snaps into. I have had to replace the headlight housing/lamp wirings harness multiple times along with many light bulbs. Second, there is a recall for the electronic power steering. My particular VIN was recalled for an electronic power steering sensor. The power steering has gone out on me while driving twice, so I brought it to the dealer. They indicated the electronic power steering motor needs to be replaced,and is not covered under and recalls. There appears tobe numerous recalls on GM vehicles related to the electronic power steering, and replacing motors for that matter, but the dealer has indicated there is no such recall related to my particular vehicle/VIN. …

Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated while driving at various speeds, the brake pedal was depressed however, the brake lights failed to illuminate. The vehicle was taken to an independent mechanic to be diagnosed. The mechanic determined that the brake module needed to be replaced. Porter Chevrolet (414 e cleveland ave, newark, de 19711) was contacted and informed that the failure needed to be repaired out of pocket. The vehicle was not repaired. The contact referenced NHTSA campaign number: 14V252000 (service brakes, hydraulic, electrical system, exterior lighting, vehicle speed control, electronic stability control) as a possible solution to the failure however, the VIN was not included. The manufacturer was made aware of the failure and informed the contact that the vehicle was not subjected to any recalls. The failure mileage was approximately 169,000.

Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated that the headlight bulbs constantly turned off. The vehicle was taken to repair shops and dealerships several times. The bulbs were replaced but the failure continued. The headlight bulb recently melted to the wiring harness. The vehicle had not been repaired at the time of the complaint. Additionally, the contact stated that the fuel gauge would fluctuate between full and empty and did produce correct readings. On three occasions, the contact ran out of fuel because of the faulty gauge. The vehicle had not been inspected or repaired for this problem at the time of the complaint. The contact called the manufacturer and was told , due to high mileage on the vehicle, they could not assist her. The current and failure mileages were approximately 60,000.

The backlighting on the main dash (behind the odometer, speedometer, gas gauge and other indicators) fails to illuminate. It started out as only a small part of the backlighting, but has progressively become worse. We just had the car at the dealership for the 3 unrelated recalls and asked them to "give us an estimate to repair". When the car was returned to us, the lighting failed to illuminate nearly the entire dash (worse then before it was in for service). We were told the module would need to be returned to the manufacturer (GM) to be repaired/replaced and then be reinstalled and would cost over $350. No idea how long the car would be out of service either. This a major safety issue for night driving!

Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated that the windshield transmission wiper linkage bushing failed. The vehicle was not diagnosed or repaired. The contact also stated that the rear passenger side tail lights failed. The contact stated that the failure was intermittent. The contact also stated that removing the key from the ignition was difficult at times. The manufacturer was notified of the failure and offered no assistance. The approximate failure mileage was 53,000.

Takata recall. My radio started displaying a service air bag message and my horn stopped working. The wiring in the car has stopped working. I began to replace lightbulbs thinking they were blown but just will not work. Heard this car was recalled for these exact problems I am having but for some reason my car has no recalls. My steering wheel makes a knocking noise when turning very sharp. Sounds like a piece is broken knocking around

Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated that the light bulbs of the headlight assembly were too high in voltage that they were leaving brown burn marks. The dealer was informed of the failure and they stated that they could not assist with the failure due to the mileage and age of the vehicle. The vehicle was not repaired. The failure mileage was 114,000 and the current mileage was 120,000.

Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated the turn signal bulbs continuously failed. In addition, the amber lens of the headlight assembly was melted. The vehicle was not inspected or repaired. The dealer advised the vehicle was not under recall. The failure mileage was approximately 48,000 and the current mileage was approximately 58,000.

NHTSA investigations

Headlight complaints in other Malibu years