The turn signal bulb gets too hot and melts the orange plastic covering the turn signal bulb. I replaced the headlamp assemblies because the orange plastic coverings had holes melted into them, and were unrepairable. I also replaced the turn signal bulb with the bulb specified in tsb #06-08-42-004B which specifies use of the osram 3157 lcp bulb, GM part number 13502322. This did not correct the problem, and I am scheduled to have the headlamps replaced again for a second time, because the orange plastic covering the turn signal bulbs have holes in it again. I first had my headlamps replaced on 07/20/2010, and today is 07/18/2011, so it has been less than a year and the problem is reoccurring.

- Hershey, PA, USA

My car's lights are melting, smoke even comes out of them.I've seen this on other 2005 Chevy Malibu and they are all doing the same thing, which means its a manufactures defect.no one at GM wants to help me, and if my car doesn't get fixed its going to cause a fire.it has burned out my bulbs very quickly and often.I took my car in to a GM goodwrench service shop at american Chevrolet in modesto, ca.the service consultant there seen my car and said that it was not normal, he brought out another 2005 Chevy Malibu that they had there and its doing the same thing.he tried to put me in contact with the GM, but I got told I was a liar, by a representative.I need help becuase there has to be a recall on the lights, before it causes a fire.check and see any 2005 Chevy Malibu and you'll see that its true.thank you for your time.

- Hughson, CA, USA