2005 Chevrolet Malibu

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. The contact stated that while driving at an undisclosed speed, the steering wheel became inoperable. There was no warning light illuminated. The contact stated that the failure was related to the U-joint in the steering column, which made the vehicle difficult to control. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 37,000.

NHTSA ID

11723407

Incident

Mar 10, 2026

Mileage

37,000 mi

Power steering failing. As I was driving down the road I got a power steering message and chime. No dash light came on and I lost all ability to turn my vehicles steering wheel. I went to add power steering fluid just to learn that my 2005 Chevy Malibu maxx LS comes equipped with EPS(electric power steering). Then I check on NHTSA for safety recalls and there is a safety recall for the Chevy Malibu maxx including the 2005 Chevy Malibu maxx. I was pulling safely out of store parking lot into traffic and I had to hit the ditch luckily I didn't get T-boned. Thanks to my reaction time being fast I made it safely outta the road. I am available to have car inspected if needed. It just started on 11/23/2025 I bought the car used a year prior in Nov. 2024.

NHTSA ID

11704639

Incident

Nov 23, 2025

The steering locked up when the brakes were pressed and the steering wheel was turned to avoid crashing with another car. The result is the crash happened and damage to both cars. Thankfully traffic was only going around 10 mph. If this had happened at high speed my son may have been seriously injured or even killed. The mechanic is working on it now and has reported the power steering module and power steering motor has to be replaced.

NHTSA ID

11700534

Incident

Nov 13, 2025

The car has a recall for power steering the recall covers the torque sensor in the steering assembly I had the recall done about 6-8 weeks ago & now I’m dealing with another power steering issue I took the car to Chevy & the whole power steering motor has failed they say it is not covered under the recall although it should be other Malibu models are this is very frustrating & unacceptable as I just got a recall for steering done & now I can’t even drive my car

NHTSA ID

11678786

Incident

Aug 4, 2025

The EPS began sporadically and severely jerking the steering very powerfully while driving and stationary and draining the battery at an accelerated rate necessitating multiple replacements of and charging 2 batteries to get to and from my job and anywhere else making everyday life very difficult beginning in early 2024. A couple months before this issue became a daily and constant occurrence in in February 2024 between the 6th and 13th I had a stabilizer link and control arm on the right side replaced and an alignment done at Firestone, on the document for the alignment it states no manufacturers recommended services necessary on suspension. The mechanic who replaced the parts told me that the EPS issue is a likely cause for the steering system damage as a vehicle is not meant to remain stationary while the wheels are forcibly turned as is the case when the EPS takes over and jerks the wheel often to the extremes of its function. I have video of this on multiple occasions and it can be inspected still occuring. I took it to Hendrick Chevrolet Shawnee Mission in April 2024 and explained the services done recently and the mechanics opinion on the EPS. They held my vehicle for 3 days not saying it would take so long, during which I had to use a truck I had just bought and was not ready to be driven to get to work, it's transmission blew and has sat since. They called me to come pick it up and only once there told me they had refused to replace the recalled EPS unit "due to loose steering" as quoted from the document Given to me. I asked them to reconsider since this was the only vehicle I had running and charging batteries and being nearly forced off of the road or into other cars daily was very concerning, they simply told me to take it to another dealership for "a second opinion" I stated I didn't have time for another dealer to hold my car for days because my truck had just gone OOC, they held their position and I drove it until forced to buy a new car in 03/2025

NHTSA ID

11678257

Incident

Jan 1, 2024

POWER STEERING WENT OUT AND WATER PUMP

NHTSA ID

11675929

Incident

Jul 24, 2025

The contact owns a 2005 Chevrolet Malibu. The contact stated that while driving at 60-70 MPH, the steering wheel turned to left and to the right independently. The traction control warning light was illuminated. An unknown local dealer was contacted, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 220,000.

NHTSA ID

11672661

Incident

Jun 11, 2025

Mileage

220,000 mi

The electric power steering has failed on me numerous times. From being completely locked and having to restart the car 5 times just to free it up, to it locking up while i'm going 70 down the freeway multiple times. one of those times was while i was merging lanes and my wheel got locked slightly left and it sent me into the median wall, luckily no more damage than some missing paint and scratches but this is a problem that needs fixed. I searched my vin and there is no recall but it is the exact same make and model and has the exact same EPS issues the other 05 malibus do. what are my options before i get into a really bad accident because of this?

NHTSA ID

11661092

Incident

May 12, 2025

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 Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.

This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking tension or probing the .64 series terminals. The test probe terminal has been released in the terminal repair kit (J-38125-620H) located in Lear Tray 7 part number 963716-2. There are 5 terminated leads in a package part number is 13505346, which can be ordered through your normal General Motors Customer Care and Aftersales parts channel.