2005 Chevrolet Malibu Maxx

GM designed the MY 2004 and 2005 Chevrolet Malibu and Malibu Maxx vehicles with a daytime running lamp (DRL) system that uses the same filament (the high power filament of a dual filament bulb) as the front turn signals.The high power filament operates at full battery voltage when functioning as a DRL.The DRL is illuminated whenever the headlamps are off, increasing the duty cycle of the front turn signal bulb.The MY 2003 and earlier Malibu vehicles (Malibu Maxx was not manufactured for sale in the U.S. prior to MY 2004) used a headlamp based design, operated at a reduced voltage, for the DRL function; GM reverted back to this design on the MY 2006 and later Malibu and Malibu Maxx vehicles. Filament based bulbs have a finite life (hours of illumination) for any given operating voltage.As a result, increasing the duty cycle of a bulb typically decreases the life span of the bulb.GM identified and addressed two front turn signal/DRL and rear turn signal bulb quality issues early in MY 2004 production, however vehicle warranty claims for failed bulbs continued to occur.To address the high warranty levels of bulb failures (90% of the warranty claims submitted to ODI by GM were bulb failures and 10% were socket failures), GM issued a technical service bulletin in March 2006 advising dealers to use a new specification of bulb when addressing service failures, and to also inspect the electrical sockets for thermal damage and replace if necessary.In June 2006 (after subject vehicle production ended) GM changed the turn signal bulb specification to that of the TSB bulb in vehicle production also.To date, ODI has not identified any allegations of crash, injury, or fire related to the alleged defect even though the subject vehicles have experienced 5 - 6 years of field exposure.ODI's analysis of consumer complaints, both VOQ and manufacturer, shows a declining trend.The warranty rate for turn signal bulb replacement is high however statistical analysis of the warranty data suggests that the majority of the original equipment bulbs have already been replaced.GM conducted a safety recall (06V-263) for MY 2004-2005 Cadillac XLR to replace the front turn signal/DRL bulbs and the electrical sockets.However GM advised that the turn signal/DRL bulbs/sockets on the subject vehicles differ from those on the recalled XLRs in several respects, including using bulb sockets with four electrical terminals as opposed to three, which improves the electrical connection, allows the bulb to operate at a lower temperature, and adds stability to the bulb in the socket; operating at a lower voltage, which increases vehicle bulb life; using vented headlamps, which allows bulbs to run cooler than those installed in a non-vented XLR headlamp; and using a clear bulb, which runs cooler than the amber bulbs installed on the XLR.Additionally, the warranty claim level related to subject vehicle sockets is unremarkable compared to other defect investigations into defective socket assemblies.A safety-related defect trend has not been identified at this time.Further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will take further action if warranted by the circumstances.See attached report for further information.

The contact owns a 2005 Chevrolet Malibu Maxx. The contact stated while driving on several occasions, the vehicle made an abnormal sound and the vehicle lost power steering functionality. There were no warning lights illuminated; however, the power steering failure message was displayed. The vehicle was taken to an independent mechanic who provided the contact with a Technical Service Bulletin regarding the repair for the power steering failure. The vehicle was not repaired. The contact referenced TSB: 14116 as a possible solution; however, the repair was not covered. The manufacturer was not notified of the failure. The failure mileage was approximately 235,000.

NHTSA ID

11581403

Incident

Mar 29, 2024

Mileage

235,000 mi

The contact owns a 2005 Chevrolet Malibu Maxx. The contact stated that while driving at an undisclosed speed, the power steering assist fault message was displayed and the steering wheel became very difficult to turn in either direction. Additionally, there was a ticking sound coming from the steering column while turning the steering wheel. The cause of the failure was not yet determined. The local dealer was notified of the failure and the contact was informed that the VIN was not included in NHTSA Campaign Number: 14V153000 (Steering). The contact indicated that the vehicle had experienced the failure listed in the recall. The failure mileage was unknown.

NHTSA ID

11484580

Incident

Sep 15, 2022

The contact owns a 2005 Chevrolet Malibu Maxx. The contact stated while driving approximately 30 MPH and making a right turn, the vehicle lost power steering functionality. There was no warning light illuminated. The contact was able to pull to the side of the road and stop the vehicle. The contact drove the vehicle to an independent mechanic, where it was not diagnosed due to the mechanics being unable to replicate the failure. The contact became aware of NHTSA Campaign Number: 14V153000 (Steering) however, the VIN was not included. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 150,000.

NHTSA ID

11454976

Incident

Dec 15, 2021

Mileage

150,000 mi

The contact owns a 2005 Chevrolet Malibu Maxx. The contact stated that while her husband was driving 55 MPH, the vehicle lost power steering functionality. There were no warning lights illuminated. The contact stated that her husband manually steered the vehicle and veered to the side of the road. The contact stated that her husband turned off and restarted the vehicle and the power steering functionality returned. The contact's husband continued to drive the vehicle. The contact stated that the failure reoccurred while driving. The vehicle was taken to the dealer who diagnosed that the power steering control module, steering control module, and torque sensors needed to be replaced. The dealer also advised the contact that she would be responsible for the cost of the repair as an unknown recall had expired in 2014. The manufacturer was not notified of the failure. The vehicle was repaired. The approximate failure mileage was 98,000.

NHTSA ID

11442826

Incident

Dec 6, 2020

Mileage

98,000 mi

TL* THE CONTACT OWNS A 2005 CHEVROLET MALIBU MAXX. THE CONTACT STATED THAT WHILE OPERATING THE VEHICLE, A CLUNKING SOUND WAS COMING FROM THE STEERING COLUMN WHILE TURNING THE STEERING WHEEL IN EITHER DIRECTION. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE CONTACT INDICATED THAT THE STEERING COLUMN WAS PREVIOUSLY REPLACED HOWEVER, THE FAILURE PERSISTED. THE LOCAL DEALER JOHN ELWAY CHEVROLET LOCATED AT 5200 S. BROADWAY, ENGLEWOOD, CO 80113 AND THE MANUFACTURER WERE NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 45,000.*DT

NHTSA ID

11408378

Incident

Apr 1, 2020

Mileage

45,000 mi

TL* THE CONTACT OWNS A 2005 CHEVROLET MALIBU MAXX. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE LOSS MOTIVE POWER AND STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO JOHN ELWAY CHEVROLET LOCATED AT 5200 S. BROADWAY, ENGLEWOOD, CO 80113, TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE TIMING CHAIN HAD FAILED AND THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT YET REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 47,000.

NHTSA ID

11408263

Incident

Apr 10, 2021

Mileage

47,000 mi

TL* THE CONTACT OWNS A 2005 CHEVROLET MALIBU MAXX. THE CONTACT STATED THAT THE VEHICLE FAILED TO START AND THE ANTI-THEFT WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER AND DEALER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS 165,000.

NHTSA ID

11256789

Incident

Jun 1, 2019

Mileage

165,000 mi

TL* THE CONTACT OWNS A 2005 MALIBU MAXX. WHILE OPERATING THE VEHICLE, THE PASSENGER AND DRIVER SIDE TURN SIGNALS MALFUNCTIONED AND WOULD NOT ILLUMINATE. THE VEHICLE WAS TAKEN TO LEWIS CHEVROLET OF GARDEN CITY (1903 US 50 BUS E., GARDEN CITY , KS) WHERE IT WAS DIAGNOSED THAT THE HEADLIGHT BULB SOCKETS HAD MELTED AND DAMAGED THE BULBS. THE DEALER STATED THAT THE BULBS COULD NOT BE SCREWED OUT OF THE LIGHT BULB SOCKETS AND THE ENTIRE HEADLIGHT BULB ASSEMBLY NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT INDICATED THAT THE FAILURE OCCURRED TO BOTH THE DRIVER AND PASSENGER SIDE ASSEMBLIES ON MULTIPLE OCCASIONS. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 160,000.

NHTSA ID

11208047

Incident

Mar 1, 2019

Mileage

160,000 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.