My low beam light keeps going out on my car replaced three times. Can I ground that headlight wire to make it work?

Change connector going to head light maybe getting a bad connection.

Check the car's alternator charging voltage. If the same bulb keeps burning out the alternator may be putting too much voltage. Voltage measured at the battery engine running should be 13.8 to 14.6 volts. Also Jim is correct, touching today's bulbs with bare fingers may cause them to soon fail. If you do touch one, use rubbing alcohol and clean the glass surface of the bulb to remove the oils from your fingerprints.

Mine the socket keeps burning out. Like mark asked can you ground them??

You may need to install a new pig tail. Loose connections can cause burnout.

My passenger side low beam light has went out 2 times, what can it be

I was having the same problem. my passenger dim bulb kept going out every 2 weeks and turns out the turn signal multifuction switch was causing the problem

I have a 2012 Chevy Malibu and the passenger headlight keeps going out. Not burning out, but quits working! I changed the bulb about 5 times before I realized that it wasn’t burning out. All the other lights on that side work fine. A few times I could tap on the headlight assembly and it would come back on. I took it apart and found that the plastic connector was broken and shorted out, so I ordered a new wiring harness that goes from the ground wire split to the headlight assembly, put it together and it worked fine for 2 days and went out again. I took the front end off AGIAN and unplugged the bulb and plugged it back in and it works fine again. I have checked all the wires and the ground screw and can’t find a problem.

I have the same issue. Weird that we all have an issue with the passenger side low-beam. I changed the headlight Nov 5th and again on new years day. It is out again but not always. This morning I hit a bump in the road and it came back on. So frustrating since it's so much work to get to the bulb. I will be trying to change the pigtail this weekend if it's warm enough out. Gotta love having a headlight out every few weeks in Minnesota winter

Maybe time to contact the Chevrolet? Strange we are all having the same exact problem. Go to WWW.NHTSA.GOV to report issue. If enough people report, they may issue a recall.

same issue here 2009 malibu, always the passenger side. High beam fine. Chevy replaced the pigtail, still going out

I have a 2012 Malibu Chevy Malibu and it's doing the same thing right weird what's going on

Yep. Same here also. 2009 Chevy Malibu, passenger side low beam. Ive changed the bulb 3 times within the last couple months

02 malibu and my headlights, turn signals, flashers, windshield wipers, and my heater blower on #5 only all go out like there is a short.... I usually can hit the dash right in the middle and it comes back on but here lately it don't want to come back on. Scares me to drive it. I have never owned a bigger piece of junk in my life!!! Less than 120,000 miles and we have rebuilt the motor. Its broke down more than its running and its been taken care of!!!

2008 Malibu LTZ, both low beams keep going out. What are the odds that both pigtails have to be replaced. Still have high beams, keep losing low beams. I'm puzzled

I have a 2009 Malibu with similar issues. After replacing the passenger headlight 5 or 6 times, I brought it to a Chevy service department. The technician suggested I purchase a partial wiring harness like I've seen pictured here. I thanked him, purchased and installed the partial harness. All was FIXED...only for about 2 years. I just noticed the same headlight is out again. So bummed out cause now I have a Power Steering, Electronic Stability Control (ESC) issue with the same car. Going for diagnosis tomorrow.

Same issue with 2008 Malibu LTZ. Passenger low beam keeps goin out. RECALL TIME CHEVROLET!!!

Same problem on my 2009 Malibu. The passenger low beam light keeps going out.

Malibu 2009 passenger side low beam went out for the 3rd time within a year. its so frustrating. Ever since i own this car, its full of problem. i wish i got money and change the car and never buy GM.

I have the same problem with my 2008. I finally just changed the whole pigtail set which literally cost only maybe 20 something dollars online. Once I changed it, I never had a problem again

My opinion, the daytime running lights on this model aren't really daytime running lights at all. They drop power to the main headlights to 30% output i believe, which the bulbs are not designed for. This is a laziness/ "value engineering" flaw. This will be my 4th time doing them today, and my plan is to pull the relay or fuse for the daytime running lights. I almost guarantee this is the issue.

We have the same issue. Low beam on passenger side stops working, followed later by driver's side stopping. Noticed it wasn't burning out the bulbs after replacing them about 5 times. Replaced the pig tail. Replaced both low beam lights. Lights stayed working for a couple weeks. Both low beam stopped again yesterday. Going to report it as soon as I can find who to report it to. Hopefully we'll get enough to report it that they'll issue a recall.

Forgot to add: Ours is a 2012 Malibu LT.

2011 Chevy Malibu Driver side head lamp went out 2nd time it went out what the hell . This bulb should’ve lasted at least a year or two . Recall to the Freaking Max!!!!!

i had the same problem on mi malibu. the passenger head light it burn out 3 bulb. i just grounded it and problem solved no more burnt bulbs.

Same problem here and I asked a garage yesterday about it. They said that they sell an updated wiring harness only from the dealer for my Malibu (2009). I will be calling on Monday and getting it cause this girl is sick of pulling the bumper off. Anyone think this will help my blinker issue I have to hold down the blinker thing to get them to work. Hopefully the new harness will change that problem too. I will let you know how I made out! If this doesn’t work I will be calling Chevy and maybe we can get a recall. My garage quoted me 150 to change it!!!

I have the same problem also with my 2012 Chevy Malibu LT I have changed the passenger side low beam twice.. The second time it worked for 3 days before going out again. Making an appointment at the dealership so they can fix it once and for all

Pull out the daytime running light relay and it should resolve the issue. Worked for me. No more daytime running lights but who cares. See my above response for the reason why this works.

I have a 2011 Chevy Malibu and I have replaced my passenger low beam bulb twice as well. I'm reporting this as well. What is the best thing to do?

2006 malibu the passenger low beam has gone out twice in this is my third time within like 6 months of changing them and my blinkers work but they don't shut off by themselves. Anybody know what the reason for that is is this all connected together?

I have a same problem with my 2012 Malibu. In March 2018 my passenger light went off and would come back on sporadically when hitting a bump. But eventually would go out again. Realized it’s not the bulb since it kept coming back on. I checked the socket and it was completely melted looking inside. So ordered and I stalled pigtail. Solved the Problem or so I thought. June 2018 same king happened this time to driver side. I knew the fix and once again fixed it using new pigtail harness. One month later and now the passenger side is out again. Based on my experience the problem is that there is excessive heat bing created and it is causing the plastic in and around the low beam socket to melt thus causing lack of contact between the bulb and the socket.

Same issue except on my driver's side. Connector keeps melting.

The same thing keeps happening to my 2012 Malibu! It's gone out 4 times in 3 years! Ughh

Same issue here with the passenger low beam headlight, it went off twice and each time I fix it i have to replace the connector. just weird how most of Malibu owners have the same issue with the same headlight!

Same issue. I have a 2010 Malibu. Changed passenger headlight/pigtails/wire harness 4-5 times and it continues to go out every 6 weeks or so.

OMG I'm not alone. I have replaced my melted pigtails 3 times now. Get up this morning and my passenger side is out again I'm pulling my hair out here. Anybody find something that works????

Bro, i feel ya. I changed pigtails and switched to leds bulbs that i ordered off Amazon for $35.00. Its been 6 months and no problems

I'm going to try getting an aftermarket relay wire harness it's like $8 and if that don't work I will try LED bulbs or an HID conversion kit.

Same issue here....2011 Chevy Malibu Guess what??? LOW BEAM PASSENGER SIDE KEEPS GOING OUT!!!! Soo annoying....yet all we can do is keep buying new bulbs and paying someone to install it everytime! I know someone said O'Rielly's or Autozone will change bulb free if you purchase new bulb from them, but not in Lafayette, LA! They claim its up to thier discretion and since Chevy Malibu is a pain in the ass to change...No can do!!

Since I got my 2008 Malibu LTZ a year ago last April, I have had the driver's side light go out twice. First time I replaced myself (being careful not to touch the glass), second time my dealership service switched it out. Has stayed working ever since. No sooner did I get the driver's side working, the passenger side started failing. Took it in today for the 4th time. (Changed harness on the 3rd time) Each time it was replaced, the duration it lasted got shorter. Just before this 4th time, it would quit at night, but work again next day, until it finally stopped. After today's replacement, lasted about 2 hours. My dealer service tech researched finding similar feedback as noted in earlier comments. Service Mgr going to confer with nearby Chevy Service Mgr to brainstorm. I'm going to see if they have considered issues noted here previously. Since retiring, one of my part time jobs involves high % of night time driving. This has literally put me out of work. One "good" thing from coming across this site, is finding out I'm not alone. CHEVROLET RE- CALL get my vote.

Found what appears to be a response from a Chevrolet Customer Care person??? within a different forum.

Chevrolet contact ??

https://my.Chevrolet.com

7-8 pigtail down 2010 Malibu. I also see the Police with one light out on their cars. Chevy Please HELP!!!!

The best way is to replace the whole wire harness. It is also the easiest way as you don't have to sodder or connect any wires. Just unplug old harness & plug in new one & put all your bulbs into it & thats it. Only $35 for harness so its cheaper than all new pigtails.

I have a 2010 Chevy Malibu and have changed the headlights several times- there was a recall on it sometime ago but i think there is problems with the wiring and now since I have changed the headlights so many times the clips and bolts have broken and my whole front end is zip tied and taped together... Note to self for next car purchase (how do you change the headlights) this has been the biggest headache of this vehicle

Just checking back in to confirm. Headlights are still good for me after pulling the daytime running light relay. It's a design flaw-- the "daytime running lights" just cut output to the main headlights to 30% or so, which the bulbs are not designed for and cant handle. Maybe the added resistance is what is causing y'all pigtails and wiring to cook (that doesn't sound right but i'm not an engineer). But i was changing them every other month and it's been 4 months since pulling that relay-- no issues.

I too have this same issue. Mine is a 2003

2008 Malibu passenger low beam out 3 times in a few months. Changed pigtails then 3 weeks later changed whole light assembly. Light is out again. Beyond frustrated!! Help

I have a 2011 and it's the passenger high beam, then 2 weeks later the driver side went out, replaced them. They worked for 2 days, then passenger went out and yesterday the driver side went out!!

Guys your lights are not goin out I have the same problem. They go on and off like there's a bad wire smh they need to find a solution adsp

Within the past 2 months ive replaced both bulbs 2x & replaced the wire harnesses in my 2011 Malibu. Its a problem especially when I was driving late at night with my son in the car and both lights went out. Luckly my high beams worked. On another note, I've figured out a way you dont have to take the whole front end off and its so much quicker!

Without taking the front end off???? Please, please tell us!!

You have to pop off the bumper a little bit on the side you are changing. Alot of it you do the same, just 1/2 of it. You dont have to remove the long plastic cover along the front under the hood if you don't want to. Remove wheel well cover as usual turn the wheel to reach the bolts you need there is like 2 or 3. Underneath it helps to pop off the tabs & ext.. Tug the bumper out enough to loosen the head light up b pull out slightly. There ya go. If you've done any of this hopefully you can get the idea. Ill try and get pictures or a video up for a visual.

2010 Chevy Malibu same problem the headlamp on the passenger side goes out.

Same issue! Replaced bulb like 10 times but high beam on passenger side has gone out now too. If I hit I hard enough, the low beam comes back on for a random duration of time. Going to look into replacing harness or pigtails. Replacing fuses today to see if that helps. 2005 Malibu is horrible for its electrical system.

2010 Chevy Malibu, same problem. Replaced right front low-beam headlight twice already in the past few months - July and October, and guess what, it's out AGAIN, early December. The high-beam is fine, but it's not appropriate to just ride around everywhere all the time with high-beams on, and for our family, every time this happens, it means a trip to the mechanic, leaving my car for most of the day, making special arrangements to my work schedule, etc. I'm also getting a service airbag light, the transmission had to be replaced at about 63k miles, and although I've been a lifelong GM car purchaser - having had Saturn and Geo's before this.... I'm unhappy enough that my next car is unlikely to be a GM product. I can't keep having this problem. so I'm starting to research other products for my next new car, much as I don't want to have a car payment again.

I have a 08 chevy malibu and just started having this issue this past year. I changed the low beam passenger headlight 3 times this year. My low beam connector is fried. I will try to change the wiring harness and i will pull the day time running light relay to see if that fixes the issue. Seems to have worked for Will.

Has anyone installed a new battery since their melting connector issue started? If so did the problem continue?

I have not installed a new battery in teh car for about 3 years now. Ok i swapped out the pigtail connector on the passenger headlight and yeah super burned out. The bulb was still good. I also pulled the DRL relay and DRL fuse (located next to the battery). So far so good. Lights only come on in the dark (at full brightness not dim). I will check back in a couple of months to let you know if the fix still worked.

My headlights come on fine when I unlock the car with the remote. Then when I start the car, the low beam on the driver side goes out, high beams are fine. It is not the bulb since it works with the remote, just when I start it. Any ideas???

Same issue with my 2012 Malibu. My passenger side went out and I switched the bulb and 2 days later went out again. Read about doing pig tails, but decided on ordering OEM Head Light Socket Wiring Harness from Ebay, the light bulb was still good just a bad harness. It's been over a month now and no issues.

Same problem here with my 2012 Malibu AND 2009 impala (drivers low beam on both). From this point on, I'll be asking about the headlights when I purchase a car. Tonight, I'll pull the DRL relay and fuse. If that doesn't fix it, I'll replace the battery. But I'm doubtful that it is the battery. It's most likely to be a wiring/component issue.

@Michael - The light that comes on when you unlock your car is not the low beam bulb. They are two different bulbs. I believe its the hi-beam bulb. @rdz - when you change the bulb check to see if it is burned out or if the connector is just burned out. If the connector is burned out and the bulb is good you probably have the same issue i did with the DRL relay. @joeyC - Be sure the bulb and connector are good before you pull the DRL relay. If your light doesn't work now pulling the relay will not help. You need to fix the pigtail connector and/or bulb first. So far my car is good with no headlight issue after i changed the pigtail and bulb, then pulling the DRL relay.

This 2011 Malibu is my worst nightmare.... have spent over $8000 on various repairs in less than a year and a half! Now headlights have gone out three times in less than 2 years! First time I paid dealer $250! Next couple of times my son did the bumper pull and replaced.... but that darn melted housing is the issue. think I’ll just travel with minimal possession, hope it catches fire, and run for the hills!! I’ve owned numerous Hondas, Mercedes, Infiniti, and VW’s... and none of them gave me the problems this hunk of junk has! After I spent thousands on repairs, I used to get letters from an attorney regarding a class action suit that was being initiated however they wouldn’t take my claim because of too much mileage. They advised me to contact GM and see if they could reimburse me something out of good faith. I never did, but I still have the letter and all my receipts so I’m may be an a$$ with them because this car has certainly been one to me..... Next car will be a Lexus or another Infiniti!

I've got a 2012 Malibu LT, changed low beam bulbs couple times both sides. About 2 months ago passenger high beam went out, month ago driver side high beam went out. Waiting for a low beam to go out now to replace all at one time to take the front end apart just once. One more time! Junk!

Seems like all are having same problem!! I have 2012 and have replaced twice in last 2 months and God forbid they make it easy to replace a bulb on this model. Does anyone else having this issue have corrosion on their battery terminal?? Mine does and I'm thinking about replacing battery to see if it will resolve the problem!! Please recall this ASAP Chevy it's pretty obvious it's a flawed setup!!

@20102010 no corrosion on battery for me but the DRL seems to have been the culprit for me. My lights no longer run during the day (since i pulled the DRL relay) but they still come on automatically when it gets dark. so far so good for my issue.

DRL seems to be the issue.It says in the owner's manual that DRL reduces the light output of the headlights for daytime running.If you reduce voltage,then amperage goes way up,and amp draw causes heat, explaining the regular melting of the plugs/pigtails.Pull your DRL relay (relay 48 on a 2011 model),replace your pigtails if they're already failed,and you shouldn't ever have this problem again.

I bought a 2010 Chevy Malibu LTZ new. A few years later, a head light went out. That is when I learned you have to pull the front end off the vehicle to change the bulb. That was a learning experience! I probably changed 4 or 5 more before I sold the car in 2016 (always changing both to be safe since I had it apart. I have spent hundreds of dollars on bulbs). That really didn't end there as I sold it to my daughter and her husband. I recently changed a burned headlight for the second time for them (I just thought they were faulty headlight bulbs). This time I removed the front end and took it to my mechanic. After looking at it, he explained there was a grounding issue by design and to get two new wiring harnesses (O'reilly's) for the headlights. I did, and had two of them that were no good! Finally after going through 4 of them (made in China) I finally got two to work. I am so tired of taking the front off the car (although I can do it in about 10 minutes now). Since it is a LTZ, I may disable the running lights as an extra precaution. It is a very good car other than that even with 200K miles, but I hope they trade it soon! By the way my sister bought a 2010 Chevy Malibu LT about the same time as I did and has never had a headlight go out.....go figure.

Will has the correct diagnosis. It is a design flaw with the daytime running lights.It reduces power to the low beams to 30% (so says the owner's manual),thus causing the amp draw for the low beams to skyrocket in DRL conditions.This massive amp draw is too much for the little terminals in the plug,so they get super hot and melt the plastic plug and the metal terminals relax from the heat and stop making good contact,which worsens the amp draw problem. Disable your DRL (daytime running lamps) by removing the DRL relay from the fuse box (#48 in a 2011 Malibu fuse box next to the battery, driver's side,check your owner's manual to be sure).

Basic electrical facts: when you cut voltage in half,you DOUBLE the amp draw. Amps determine what gauge (thickness) of wire you should use to prevent overheating from too much resistance.The Malibu owner's manual says daytime running light system drops input voltage to the low beam bulbs to 30%!!!!! That's less than one third!!! How much amp draw must the bulb and wiring handle to allow the bulb to work? Remember,fifty percent voltage doubles the amp draw,and this system drops the voltage below one third!!! Daytime running lamp system is a major design flaw!!!! I can't believe it passed GM Quality Control,and for several years,at that!!! Disable your DRL system,the lights will still work normally when you cut them on.

Thanks so much Amhermshawn! I’ve replaced the lights over 4 times in the past year or two and am on my second Lifetime Warrenty LED lightbulb. Bleh. I have noticed, however, that my DRL’s are always on and wandered about that. I’ll be pulling that fuse and only show up here if I have the problem again! Cheers Euell

2012 malibu same stuff. Wack hard and it comes back. Multiple bulbs a year. Removing half the front bumper to replace too.. Defrost has died, cigarette lighter port died. Both door speakers stopped working... Yikes.

My 2008 LTZ has recently been having intermittent passenger headlight outages. I accidentally discovered that they seem to work correctly when I use the remote start feature, but then when I insert the key and turn the switch on, the passenger light goes out. Somebody explain that to me. FWIW, I had them replaced by a shop about 18 months ago when a friend noticed that the passenger light was out.

I used to thing the same thing about my headlight. Use the remote start feature and look at which light bulb is actually on (it should be the high beam bulb, not the low beam bulb). Compare which light come on with the working headlight. You have the DRL issue that we all have. Read the above threads to find out more. Usually replacing you headlight connectors (pigtails) and removing the DRL relay fuse (#48 in the battery compartment) fixes the issue. I did this in my car over a month ago and it fixed mt issue. I also have a 2008 Malibu

Same here. Passenger side headlight has went out every other month or so. The last time I was getting it change (you have to take the bumper off) it popped back on. It went out again yesterday.

been dealing with this for a few months. had an idea, gonna try taping over my light sensor on dash so it thinks its night constantly so no DRM just full headlights all the time. hopefully that does the trick, sure shorter bulb life but better then replacing plug once a month

@Tasha read above for fix to your issue. I had the same issue and i replaced the relay connectors (pigtails) and pulled the DRL relay (located in the fuse box #48 next to your battery) and my issue was fixed. @Michael pull the DRL relay, by pulling the relay your headlights will be on @ 100% always. It was easy to do and fixed my issue.

Put a zip tie around the connector. That fixed my problem. It was a Loose connection.

@syndrome85 I printed out your suggestion and I will take to the mechanic with me. I don't know how to do it myself. I hope it works.

I have a 2012 Chevy Malibu with the same issues. A year ago I actually had a bulb burn out and found out how much fun it was to change. I replaced both low beam bulbs. A month ago the passenger low beam bulb went out. I removed the bulb and noticed it wasn't burned out so I put in the old bulb and it worked for about a week. It went out again. Repeat process. The driver's side went out then the passenger side. I wish I knew that this was a common problem and read all of these posts before swapping bulbs all those times. I would have fixed it properly the first time and saved lots of hours. I purchased 2 new wiring harnesses(part#15930264) from CARiD for $65(harness,tax,shipping), got them 2 days later, installed them and pulled the DRL relay(#48) today. All lights are working. I will keep you posted if I have other issues. Thanks.

@ RickS262 So far so good with my headlights. I have a few months now with no issues and i'm hoping it stays that way.

I was having these same issues with my ‘06 Malibu Max with the passenger side headlights. Found a broken ground wire. It was broke inside the insulation—no outside indication as to where the wire was separated.

2014 impala mileage is 66,000. Purchased in Jan 2018. Have changed low beams 5 to 6 times. Only thing I see that maybe the real problem. When turning the ignition on to start low beams come on, then while starting, low beams go off, then after engine turns over and begins running. Thinking maybe a CCA (cold cranking amps) power surge is getting to low beam bulbs. How to disconnect the ignition switch wire from starting circuit and low beam lamps??

Hello everyone im havingsame issue with 2012 i havexhanfed bothsides 5 times aince 10/2017 once i get one replaced the other one goes out i have contacted cheverolet there is no recalls tired of being issued citations due to this issue for improper equipment. We all need to file a cpmplaint because this ridiclous..... just replaced driver two weeks ago now ot needa to be replaced again.

@gorgeouz Read above. Sounds like you need to do what i did. Replace the headlight connectors (again) if they are burnt out, and pull the DRL relay (#48) in the fuse box next to the battery. So far so good with this fix in my '08 malibu. Headlights are on full instead of 30% with the Daytime running lights (DRL). No more burned pigtails (headlight connectors). People here have tried this fix and so far so good. Since you replaced it so many times, you might as well try this fix.

I need clarity. I replaced the pigtails and bulbs, pulled fuse 48 and 46 which were the DRL fuses but my daylights still come on. Are the supposed to still be coming on? I assumed with the fuses removed, I'd had to manually turn them on. Also, I did this about about almost a month ago and so far so good.

@Tasha - yes your day time running lights will still come on. The DRL fuse (#48) only limits the power going to your headlights. I believe it only allows 30% of power to the headlights, which is the issue. Your daytime headlights are now @ 100% lighting, which in my opinion is better. If you leave your lights on auto they will come one when it's dark and turn off when it is bright outside. Hope this helps.

I have a 2010 malibu and the passenger low beam keeps going out...fixed it 2 times now and both within 4 days went out...not including the pain to take off front bumper...its very frustrating and I am going to try Wii advice pulling the daytime relay switch out and see if this works...hopefully because these bulbs add up and the time to fix...and we can get a ticket for the crap if u drive at night...c mon gm!!

I've had the same issue and what I've come to realize is that even after changing the pig tails the bulb itself isn't being held in very tightly by the side slots and it wiggles away ever so slightly from the connector. I'm unsure if this is an issue with the makers cause the original seemed to have a more heavy duty slot holder for the bulb but due to the connector melting I had no choice but to change it.

@Wdmnt711 The Turn Signal Blinker issue is the column switch Youtube "Chevy Malibu Blinker FIX FREE!!!" I bought a new one and I cant recall the exact fix for it but I was able to fix the old one.. it was like something slipped off so the left turn signal wouldn't stay on.. there is plenty of free guides on youtube and it's fairly easy just take pics at each step if you need to help you put it back together...

At togas and most of the other people, check your module by the feet rest on the passenger side. Look up my youtube channel weekend wrenches.

I am having the same issue with my 2011 Malibu and need answers. My headlights on both sides only work sometimes, almost as if there is a shortage. If I hit a bump they go out and won’t come back on unless I am hitting on the car or hit another bump the right way. It’s dangerous and scary to be driving now the road and all of your lights go out while it’s dark outside. Now my switch for the lights won’t even turn my lights on except when it wants too. I can turn it on a million times and it may or may not turn the lights on. I am going to Chevy in the morning but it looks like I will be selling my car because I can’t afford to continue to fix the lights over and over for a problem that really is Chevy problem. It has to be a recall problem.

I am having the same Low Beam "shortage" issue with my 2011 Malibu! For awhile, 1 light was out. THEN, the other NIGHT I went to drive and BOTH were out. Brights worked, but that's no good for oncoming traffic. I just had my bulbs changed less than a year ago, and figured that couldn't be the case. That was knocked completely out of game when they both decided to come back on! Today they've gone from both working, back to 1 working. I followed a previous posters instructions and went to https://www- odi.nhtsa.dot.gov/VehicleComplaint/ and filed a complaint. (You do need your VIN) I highly advise we all do this so a RECALL can be issued. I don't even want to know how much it'd cost to first FIND the issue, THEN get it fixed.

In looking at previous posts, I see disabling the DRL #48 (for 2011 Malibu) should "fix" the issue. Is that a safe thing to do? Will it cause any other issues in the future having that fuse out?

Pulling relay #48 out to disable the daytime running light system is safe.Headlights will still work normally (after you replace the probably melted plugs/wire pigtail on both bulbs).The problem with the design of the DRL system is that it drops the voltage to the halogen headlamp bulbs to 30%.This is something they weren't designed for.Halogen bulbs draw a huge amount of amps under normal conditions,so if you drop voltage, amperage has to go way up to compensate.This causes a ton of heat,which ends up melting the plastic electrical plugs and causing the lights to go out,even if the bulbs are still good.

I just spent $330 to replace ALL front lights on my 2011 Malibu. Six weeks later, driver's side light is out. I advise EVERYONE to file claims at WWW.NHTSA.GOV so we can get a recall on the Chevy Malibu.

I have the 2011 malibu and the pigtail connector for the dim headlamp continues to melt. All the components except the harness were replaced. I’m about to file the claim.

Everyone PLEASE file claims with Chevrolet and NHTSA! My driver-side low beam just went out again exactly two weeks after replacement. Chevrolet's claim? People complain about it on the internet but not to Chevrolet. That's Chevy's way of saying that until there's a recall, they don't care. If you are having these headlight problems, PLEASE REPORT IT!

Since GM apparently is not willing to issue a recall on their inferior product, I suggest either purchasing another brand of automobile or just use your Malibu as a daytime vehicle, unless your are in Canada where DRL is required! I have a 2009 Malibu that I use as a tow vehicle behind a motorhome and use mostly for day time use. I have also changed the passenger side lower beam bulb three times, also pulled relay/fuse for DRL, but still have the same problem! Will have to change/repair it again for state inspection!

Hey, I know this topic is old, but I was having the same issue, several times, after a lot of fiddling, zipties, and even a hose clamp, I actually took a good look at the connector. Mechanic or previous owner had obviously used a rotary tool to take off some plastic so they could use a bulb of the right ratings but with a different connection type. I gave up and hotglued the #@"$ing thing together. Works fine, but it's going to suck when I do need a new bulb!

Goign to try pull the DRL relay and replace the wiring harness and bulbs. Hopefully that will do the trick!

I just put in my complaint to WWW.NHTSA.GOV. If you have not, please do so. Let's get this taken care of, because it's one thing that pisses me off. Money wasted!

I did too. I got a response July 30 basically saying it's under review. More people need to do this!

I recently got a 2012 Malibu July 13, 2019. Two weeks later the passenger headlight was out. Since I had to have the light changed I decided to buy two and have them both changed, no point in tearing it all apart for a second time or so I thought. Last night I noticed the passenger side is not working again.(Oct. 3, 2019) After reading here and seeing its a common problem I reported it to NHTSA and then to Chevy via email. I was in an online chat with Chevy but the rep just kept saying I needed to take it to a Chevy Dealer to have them inspect it. I don't have money to pay Chevy to tell me what I have found to be the problem by reading here. The only way to get this issue on a recall list is by reporting it. I was told they have some complaints but not enough yet to classify it as a recall need. Please report this issue if you are experiencing the same problem. https://www-odi.nhtsa.dot.gov/VehicleComplaint/?

I have replaced the pigtails twice, pulled #46 (not #48) DRL fuse, and I am still experiencing this problem. I did not know #48 needed to be pulled as well; however, just from pulling #46, my headlights no longer run during the day, so could #48 be affecting it even though the headlights don't run during the day? My next and final step is to replace the pigtail again and pull #48. If the pigtail gets fried again, I might just lose my mind. PLEASE EVERYONE, report this problem to WWW.NHTSA.GOV. PLEASE.

Our keeps going out as well. We replaced the bulb at least every 6 months. Now we are having another problem. We must hit the headlights to make low beam work. Both sides. Ive also noticed lots of other cars same make and model with only one head light working. Chevy Malibu

Shame on these clowns for reproducing the same problem year after year, I have a 2009 and have changed both low beam pigtails, had the front off this &&^^%$ pig more time than I care to count and here I am again both pigtails melted....again. Going back together knowing it wont be the last. I feel you alls pain.

We have a 2009 Malibu LTZ in Canada where DRL are mandatory. It has 105000 km or bout 65000miles. Bought it bout year ago and have replaced both sides low beams 8 months ago with hi end Sylvania and drivers side again today. Those have a bad rep for short life as they burn hotter. Took bout 15 min to change the the one side. Sockets are good when checked today. As DRL are mandatory here we can’t pull relay. I like the idea of tape over dash sensor to let them run all time to protect the socket but will burn bulb sooner. Alternative to go onto Amazon or eBay and get a wiring harness extension that plugs into your harness before it melts with short extension that is high heat compatible. My QUESTION.... does anyone here have same burning bulb or melting harness issues with LED bulbs in low beam??? As they burn much lower amperage and heat and apparently are brighter and last much longer I’m thinking that’s the answer. I switched to LEDS on GM van and Altima bout 6 months ago for more life and none have burnt yet. Thanks.

I’ve had the same problem started about 2 years ago. It has gotten worse I put my complaint in today I’m tired of taking off the front of my car just to have a temporary fix

For all that's wondering why they headlight keeps going out. I been having this same issue with mine's as well. After taking this front end off 40 time's over & over. I have found out that the bulb gets so hot, it melts the 2 grounds 2gether at the base. No matter how many time's i change the wires. It continues 2 melt the same way.....

I have a 2012 Chevy Malibu LT. And I am witnessing the same problems with my low beams.

Wow! I have a Chevy Malibu 2012 LT and I am experiencing the same issues with my low beams.

What worked for me: I pulled the relay for the running lamps; Changed the pigtails; Removed the halogen lights and replaced them with Auxbeam Series H11 LED lights. Been free from problems since May 2019.

I just filed a complaint with NHTSA. I'm also going to try these steps above about pulling the relays and changing the bulbs (LED) and connectors. I would encourage others to file a complaint as well.

I’ve problem free for months now. I removed the fuse for the daytime running lights. Your manual should indicated which fuse that is. I actually like it better. Lights tie off and on automatically depending on light rather then being on all day.

I could be thinking about this incorrectly, but if the DRL fuse is pulled, then the DRL will still turn on at night and so at night will still reduce the voltage going to the headlights which will increase amps and therefore increase heat and lead to burnout of bulbs/connectors. Is that correct? If so, it seems like removing the fuse will help with issue during the day, but during night driving, there would still be an issue. It seems like this would prolong the lights but not completely prevent them from premature burnout. The LED bulbs that were suggested a few posts up appear to only use 30 watts rather than 55 watts like most halogen bulbs, so i'm wondering if BOTH removing the fuse and using these LED bulbs would even further prolong burnout? What do you think?

I have a 2011. I don't even know how long I've been having this problem at this point, but it is beyond frustrating. I tried changing to "lamer" halogens; they worked for some time, but are, once again, both out. I, too, have noticed MANY Malibus with 1 light out since reading this forum. I don't know how this hasn't become a recall issue. Maybe more people need to report to WWW.NHTSA.GOV? Additionally, how many car repair facilities are making bank from changing "burnt" bulbs that aren't actually shot at all?! I think my next move will be to change the pigtails (to Dorman - Conduct-Tite High Temperature Headlight Socket H8/H11) AND change the lights to Fahren H11 LEDs. I don't want to do 1 "fix" and not the other, only to have the lights stop AGAIN and have to remove the front end AGAIN. RIDICULOUS!

p.s. I pulled the DRL relay and it didn't do anything for me -_-

Mines lasted 8 months, with the suggestion of pulling the DRL fuse and changing the pigtails. They are out again now. Longest its went without going out.

I have a 04 Malibu LTZ and I have replaced my low beam passenger side bulb at least 3 times over the past 5 months. Does anyone also have shifting or transmission problems with there Malibu’s? This seems to also be common.

Only way to fix the problem, trade or sell your Malibu! Wish i would have done my homework before buying!!!

Amen!

Has anyone tried manually turning the lights off every time you get in the car? I know it’s a pain but I don’t want to pull the wrong fuse!

It was nice being part of this thread. I’m saddened to say I have gotten rid of my 2012 Malibu after 152,000 miles and 5 headlight harnesses, and removing my bumper well over 10 times. But I’m happy I won’t deal with that any more. I have upgraded to a 2019 Malibu and I’m happy to report this problem is no longer an issue.

I had the same problem just like everyone here. Took that bumper off at least 8-10 times. What fixed mine was changing the pigtails and replacing the low beam lights with LED headlights. For some reason, the manufacture lights burn to hot and they short out the pigtails. After switching to the LED's, I have not had any problems. It's been a year. Hopes this helps someone.

I am dealing with my 5th time with the right headlight out...changed harness also. 4 times already in 2 years now out again. 125$ each time it goes to a shop to get fixed

Next time you change your bulb, check the pigtail connector where the H11 bulbs fits. You will find it’s black inside from the heat of the lamps. For some reason, those bulbs burn too hot. Change out the pigtails. And then change the H11 headlamps to LED. They plug into the same connector as the H11. Their not expensive: $25-$30. Their brighter, and they have mini fans built in each one. Have not had any trouble from my headlights since. It’s been a year!

Somebody told me they replaced harnace with a none metal harnace because it caused electric interference

Has anyone figured out the issue here yet? 2011 Malibu Passenger side wont work. Changed harness amd bulb. Driver side works when it wants. Some days it goes on most it stays off.

I have a 2011 Chevrolet Malibu 2011 my headlight is out right I have to replace once a month on both side

2009 Malibu with passenger side low beam issue' Used high temp connector and grounded it directly to ground side on battery. As of this writing, seems to have resolved the problem with the inferior wiring problem on the Chevrolet malibu

OMG can i just set my 2012 malibu on fire , i am so tired of this headlight . helllppp

I had the same problem just like everyone here. Took that bumper off at least 8-10 times. What fixed mine was changing the pigtails and replacing the low beam lights with LED headlights. $30 bucks on Amazon. These LED lights have small fans installed in them. For some reason, the manufacture lights burn to hot and they short out the pigtails. After switching to the LED's, I have not had any problems. It's been a year. Hopes this helps.

Have had same problem with passenger side low beam headlight on a 2009 Malibu, changed socket and grounded it to negative side of battery. So far no problem!

Have a 2008 malibu that just started having the same issue. On my 3rd time replacing the bulb i noticed the connector u plug the bulb into was melted. Just got done replacing that and 15 min later it's out again. Sounds like disconnecting the relay should work. Like others have said GM should be ashamed of not only putting a product like this out, but of doing it over and over for at least 4 years. Oh and it happens to be the same 4 years they thought it appropriate to have to take the bumper off to change the light/harness/pigtail/etc. And to top it all off they don't even issue a recall? I'll pull the relay... Seems to be the major issue. Thanks to all of you who helped out here with this problem. I will update if the suggestions don't work but im pretty hopeful they will

I pulled the relay. It only stops the headlights from coming on in the daytime. What remedied the issue for me was ordering both sides of the headlight pigtails connectors from an auto parts store, installing them, and replaced the lowbeams with LED's. (they cost me about $30. Have not had an issue since. It's been a year. Just saying, It really works!

2012 Chevy Malibu. All the front lights keep going out. One after another. Like every 6 months. And because mechanics have to remove the bumper to change the lights, it’s over 100 bucks just in labor every time a bulb goes out. Several hundred dollars a year. Just to exchange bulbs. And now I’m going through the same problem again when I just changed all the front lights in February. It’s July. Five months ago. Seriously. I need a solution. Reading all these messages it sounds like pigtail connectors, whatever that is, may be solution. Help!

Omg I. Having the same problem with my 2009 Malibu, thought my passenger low beam was blown so bought new one and took my front end apart my self just to find out the bulb wasn't even blown.my step- dad took over and the plug the connects to the bulb seemed lose so he tried fixing and gluing it to fit tighter and it lasted maybe a month and out again.they need to put a recall out unless GM doesn't even know what is causing the problem. I can't afford to keep taki g my car apart and fixi g the same problem. And to top it off getting pulled over for head light out.its too much of a hassle and I love my car just not the problem! How do I file a complaint?

Had same problem, change plug (pig tail), ran groung wire back to negative side of battery and no more problem!! If it does recur my next solution will be to discontinue purchasing GM products with their inferior cheap wiring!!

Same issue here 2009 chevy malibu except it's driver's headlight. have seen at least 1 melted socket so far. local autozone has Novita Fog Light Bulb Socket SC08 and ZEVO LED Headlight H11ZEVOLED. o'reilly has "TechSmart 2 Terminal Headlight Wiring Harness Connector" which is designed for high temp. going to get probably o'reilly connector with autozone LED and hope for the best.

there are some harnesses that have only 2 wires coming from the headlight. First attempt replaced the headlight socket with a pigtail... worked for awhile but the light was old and failed within a year. Socket also seemed to start melting shortly after replacing the old light which lasted about a month.. Pulled the DRL Relay the first time along with the fuse I believe...but the same ac delco wiring harness known as OEM has two different versions.... one has only two wires to the headlight and the other has 3. I assume the 3rd wire is the ground and is also part of why the socket keeps melting.. has been about two months now since installing the OEM AC DELCO 3-WIRE to headlight Harness.. and no problem so far.. still have DRL Relay pulled and made sure new light build installed with gloves on so no oils, used dielectric grease in socket

Bulbs lasted A WHOLE TWO WEEKS this time! Smh. Tried telling the mechanic it wasn't the bulbs...this issue should be a recall and is beyond frustrating! I've done the www.nhtsa.gov. Maybe we should all do a complaint daily and we'd get somewhere -_-

I was about to change the headlight on the driver side of my 2010 Malibu today. But I realized that the pigtail was burned out. I am glad I did not waste a new bulb just to have it burn out within a few years. I had replaced it 2 years ago. There should be a recall for this issue. Clearly this is not something that is random and GM knows this.

I had the same problem, BOTH low beams wouldn't come on. If I rapped the side of the car near the headlight it would come on. Had to do it on both sides if both were out. Read through the threads above and decided to buy new pigtails (Dorman 645-539) through Amazon. Removed DRL relay. Also replaced the bulbs with xenon bulbs from O'Reilly's. That was about a year ago and have been working since. The post about the DRL system reducing the voltage to the bulbs made sense to me. I found my pigtails were essentially burnt at the connectors.