Fix Constant Headlight Bulb Burnout on Chevy Malibu

If your headlight bulbs on your Chevrolet Malibu keep burning out this video may solve your problem.

[@andrewbond8319]

Here’s the link to the part on Advance Auto Parts website. shop.advanceautoparts.com/p/dorman-techoice-headlight-socket-and-connector-wire-harness-assembly-645-539/11499485-P?searchTerm=645-539 Also another tip is to pull the fuse on the daylight running lights. Since these cars are manufactured in Canada the head lights stay on all day. Some online including myself believe this may be the cause of these headlights having so many issues. Just look under the fuse box cover to find the one that controls your DLR. Keep in mind that this could decrease the visibility of your vehicle during the day.

[@chickenfarm09]

Previous generations had daytime running lamps too and no problems with lights burning out.

[@franklinfowler1635]

Dorman 645-539 Headlight Socket And Connector Wire Harness Assembly Compatible with Select Chevrolet Models a.co/d/8bLVujw It's a bit cheaper on Amazon 👍 Thank you for the helpful video!

[@Stephon723]

@@chickenfarm09 I'm here because of this exact problem. And I've got a 2007 with daytime running lights.. In fact this is my 2nd 2007 Malibu. The prior had the exact same issue as well. I'm glad I don't have to take the bumper apart to change this headlight. Think I'm gonna do a simple bulb replacement today. This happens again I'll be changing out the wiring harness. Hopefully advanced has one That will fit my older model.

[@busstophere]

Thank you so much I shouldn't be surprised that chevy didn't or wasn't more responsible in helping it's customer solve this problem.

[@Kaafir_]

Thanks for sharing, my chevy malibu 2009 headlight(low beam) keeps on bugging me for months now. I have replaced the bulb 3 times and now I know why.

[@chickenfarm09]

So do you people report this to NHTSA or demand a recall? This is another safety issue that GM needs to address. Just pulling the fuse is reducing the safety of the vehicle. DRL is very helpful to make the vehicle be seen a little better. With so many distracted drivers on the road, I think it helps, and they aren't annoyingly bright like so many of the LED.

[@TheRealDarkbreeze]

Are you Canadian? In Canada there is often lower light conditions due to it's geography, weather patterns, etc. In the US, we don't have such problems during the day AND there are already requirements for all new vehicles to have automatic headlights that come on below a certain lighting threshold. What possible reason or benefit could there be to have daytime running lights mandated if low light automatic headlights are already required? Nobody is going to recall anything that was never required in the first place on a vehicle that's already 12 years old. And if a driver is distracted, daytime running lights aren't going to do a damn thing. Full on headlights don't stop drivers from being distracted and causing accidents whether it's day or night, what in the world makes you think running lights would?

[@jamesjirik2245]

I would have to get my replaced sometimes every month at Walmart because it was the cheapest otherwise it cost me like 60 bucks this sucks there should be a lawsuit or like some of the saying a recall and put this proper wiring system in because it’s obviously faulty from the factory.

[@heatherelizabeth364]

OMG ur awesome! Thanks bunches for the video

[@emartinez6584]

A couple of years ago my headlight bulb connection keeped melting to the bulb , after doing my homework , found out to remove the relay that activate the daylight cause it was melting the wire , I still have headlights in the daytime just not in daylight mode, Thats supposed to remove daylight glare by dimming the lights that makes the wiring overheat might be relay 87 not sure , will check which if someone needs info .

[@andrewbond8319]

Yes I agree 100%. I forgot to mention this in the video. I put it in the pinned comment. Definitely do this after replacing the wiring harness or you’ll be replacing it again in 6-12 months.

[@josueticas9998]

thanks how do you do that ? i just replaced the whole wiring and it's out 2 days later

[@ronaldfuhrer]

How do you do that?

[@justbizzness]

I had that same problem. One question..you mentioned other wiring issues, have you had different random messages on the HUD? I've had Service Airbag and Ice Possible pop up for no apparent reason and the rear defroster stop working even after changing the fuse. Can those be wiring issues?

[@andrewbond8319]

I actually had a 2010 Malibu that had tremendous wiring issues. It would go into reduced engine power mode periodically. Dealer practically re-wired the entire car because it was an issue with the accelerator pedal and could never figure it out. Fortunately it was still under warranty. Finally the dealer traded me out for my current Malibu and sent the other one to auction.

[@armyrunt01]

I've legit had this problem for 2 years and I've replaced the head light twice and the mech keep charging me 200 for the whole deal every time

[@Maggles69]

Yeah the headlights are a bitch and a half to replace but its something you can totally do in your garage. I wouldbt be paying a mech for this service

[@secamend]

I'm about to replace the entire headlight assembly because of this and moisture in the housing. I can't find the right bulb number for the side marker bulb, Not the turn signal bulb. Thanks.

[@praterjohnwfg]

I’m not going to explain how to get to the headlight…*proceeds to rant

[@andrewbond8319]

lol yes! Most poorly designed headlight I’ve ever seen.

[@austinpack101]

Great video. Was this a long term fix for you or did the problem resurface?

[@laura8ice]

I have to fix it at least once a month. Omg it's awful. I've had several strangers stop me and tell me they had the same problems

[@andrewbond8319]

Have you tried my fix yet? I hope it solves your issue! Make sure to pull the daylight running lights fuse as well. I wish I had shown it in the video but that’s what causes the wiring harness to fail in my opinion.

[@laura8ice]

Yes! It worked thank you!!

[@boruto9223]

@@andrewbond8319what fuse is the DRL and where is it located ?

[@jamesjirik2245]

Ill never buy a chevy/Gm product again. I changed bulbs over 30 times.

[@jophillips2868]

What caused the wires to melt If you don't fix the reason it will still continue

[@andrewbond8319]

Daylight Running Lights… pull the fuse. I forgot to mention that in the video but it’s in my pinned comment.

[@PoloRapArtist]

@@andrewbond8319 so pulling the fuse will stop it from burning out? If so I’m on it today, just went thru a few bulbs and a wire set 😂🤦🏽‍♂️

[@andrewbond8319]

@@PoloRapArtist I replaced 3 sets of bulbs in 12 months. Replaced that wiring 10 months ago and pulled that fuse and haven’t had an issue since. I hope it works for you as well!

[@sanfzipp]

I am showing 2 fuses labeled daylight running lamps. Is it correct to pull both?

[@nikitalawrence1368]

Did you have any issues after replacing the whole wiring set?

[@andrewbond8319]

No but make sure to pull the daylight running lights fuse.

[@YouTubeWowzer]

@@andrewbond8319 why are you supposed to pull the daylight fuse? I replaced entire wiring set in my 2008 Malibu and still just have parking lights…

[@oroque3144]

Do i need to take off the daylight relay or fuse?

[@emartinez6584]

yes to stop wiring from melting to bulb .

[@sadiemarshall6515]

Did this fix the issue long term?

[@brianmckenzie3926]

Great video

[@shayarzachary]

definitely not $32, more like $52. this better fix the problem, seeing as how I'll be out over $100.......

[@kellymc341]

I'm going with LED lights and need about 2 inches of space between the body and bulb would you know how much space there is

[@tsstinson]

I just put LED in mine. I had enough clearance. Mine is a 2012.

[@fakenews8324]

@@tsstinson is you leds still working ..thinking about doing that for mine

[@kencolvin8613]

You don't have to pull off the bumper cover you can go through the inner fender lines

[@JorgeGarcia-ls1qy]

Send me the part number on the

[@andrewbond8319]

644539 Advance Auto… also pull daylight running lights fuse to prevent future burnout

[@08soloblade]

Im having this problem and replaced the connection. Now its melting the new one

[@andrewbond8319]

Did you pull the daytime running lights fuse?

[@08soloblade]

@@andrewbond8319 no

[@dalemihocik4732]

@@08soloblade Upgrade the connector to ceramic and that solves the problem. Disabling a safety feature, daytime running lights, is dangerous and foolish since that's not the problem.

[@mlez7197]

part number? thank you in advance

[@andrewbond8319]

645539 at Advance Auto… make sure to pull the daytime running lights fuse as well to prevent future problems.

[@mlez7197]

@@andrewbond8319 you are a Hero ....thank you thank you thank you

[@dadoni2000]

@@andrewbond8319 why’s it important to pullout the daylight running fuse ?

[@andrewbond8319]

@@dadoni2000 I think that’s where the voltage problem is that causes the wiring to burn out

[@kal-elsonofjor-el5770]

I just replaced wire harness.. and it still burning out. The wire harness doesnt fix issue. You have to know whats causing it to burn out... 🤔

[@tsstinson]

…. It’s my first day…. I’m talking about the fuses for the daytime running lamps.

[@tsstinson]

Did you pull out the fuses for the daytime running lights?

[@kal-elsonofjor-el5770]

@@tsstinson yes i did.. both the fuse and the relay to the daytime running lights. But i didnt do so untill the new wire harness burned out. So i simply cleaned the connectors of burned materials. From the headlight as well as the wire harness. It seems to work for now..

[@crazythingis]

@@kal-elsonofjor-el5770 maybe use led that have a fan because it might just be the halogen light gets too hot especially if you drive a lot during the night

[@JesusFlores-lc4lv]

Buy pigtails splice and done

[@dalemihocik4732]

NEVER disable a safety device, daytime running lights, that's foolish and dangerous. The problem can be easily fixed by replacing the plastic connector with a CERAMIC one.

[@shayarzachary]

part # ??

[@au75bolt]

Maybe it worked beter after because of the way the camera s floping around. Ya goof!