My 2006 HHR has charred melting plastic lenses on both sides in the front that have melted through the orange plastic turning them black with holes next to the bulbs. They look like crap. I am told that this is a design flaw and that even if I spend almost $1,000 replacing both headlight assemblies it will likely re-occur.

I can't imagine being able to sell or trade in a car that looks like it has bizarre electrical problems causing charring and melting lenses. It looks like a fire waiting to happen.

Any thoughts?

 

Welcome to the site

I have seen this problem before it only happens on the 06 hhr's because in 06 the running light are used as the day time running lights. After 06 they use the head lamps for the DRL's.

Here is a link about this problem also. https://www.chevyhhr.net/forums/showthread.php?p=432831

I myself would replace the head light and install led bulbs in the running lights. The LEDs run much cooler so it should not happen again.

 

And, there have been a few reports of the wrong bulb in there.

 

to the forum!

Good info in posts #2 & #3, and whomever told you it would cost over $1,000 to replace the headlamps needs a good swift kick up the backside.

The part numbers for the headlamps are in the thread below, you can find good quality aftermarket lights starting at around $65 each.

https://www.chevyhhr.net/forums/commonly-used-part-numbers-68/part-numbers-elusive-common-parts-broken-into-separate-posts-thread-48833/

 

You could try removing the bulbs, breaking out the orange lenses, then replacing with Amber bulbs. Probably need to remove the headlights though.

 

And get them apart and find one of them weird tips for the screw to get the amber lens off. if you do it and stick in led switch back markers it will look like this.

cept it's a fall edition.

here is where I found them http://store.ijdmtoy.com/Switchback-...3157_sku39.htm