I have a 2006 HHR. The front turning signals/running light lens (yellowish orange) melts. I was once told it was a known defect in the early models caused by the bulb being too hot. The lens begins to crystalize and melt, then turns black. Eventually the socket melts and the lights won't work anymore. A few years ago I was told on this forum (but didn't retain the details) that the solution was to run some kind of LED bulb instead of the factory bulb. At 200,000 miles I spent a lot of $$ restoring the power train, suspension, and other things including both headlight assemblies. I discussed this with the restoration shop and they assured me the issue had been corrected in the new headlight assemblies. WRONG! Its been less than a year and they are melting again.

Does anyone know the details about how to swap the factory bulb with the correct LED or lower voltage bulb? What bulbs should I use and where do I get it?

 

The problem is unique to the 2006 models because they used the turn signal amber lights for the Daytime Running Lights (DRL's). 2007 and up used the headlamps for the DRL's.
Since the 06 amber lights were on anytime the car was running, they could and did create heat (I guess GM knew of the problem and changed it in the 07's and up )

Disclaimer here.
You could just pull the DRL fuse and go without them. I know my 2010 has a separate fuse for them. I would think the 2006 does too.

EDIT: I don't see a separate DRL fuse listed in the 2006 owners manual. Sorry.

 

The factory bulb is lower powered than the bulb most parts stores will tell you is the replacement. 3057KX is the correct clear bulb. The Owner Manual is wrong.

You probably have 5702KA, that is amber or 3157K clear and correct for cars that use headlights for DRL.


You could get 3157 LED bulbs, be sure to get ones with built in resistors compatable with CAN bus.

 

Yeah, My stock housings had melted too, part of the reason I got DEPO housings that do not have the lens. The DEPOS have been fine for the two or so years Ive had them installed. I bought the HHR in Sept of 2013 and have never touched the turn signal bulbs. I prefer the look of the turn signal DRL over the headlamps, gives a more "mean" look.

 

Thanks! Great information.

 

As a one-time bulb warranty guy at another OEM, I can say these guys hit it all correctly. The problem is the constant use as DRL, which I consider a safety feature, and personally wouldn't disable.

You just need a better bulb. It has to have a K in the suffix, and the extended life ones have the X. K is a Krypton-filled bulb (not just air)...

 

Not Krypton!! Uuuggghh!!!

 

RESOLVED. I had something being described as a "relay switch" removed. DRL in the front headlight assemblies are now disabled. I realize its a minor safety issue but to me its better than having the amber turn signal lenses melt, turn black, and ultimately ruin the bulb holder socket. It was simply unplugged. The part is grey, about 1 inch by 3/4 inch, by 1/2 inch with four prongs. There are two part numbers. MFX 0530609A and VJ28-911-24-Z06. Unplug & Go!

 

2006 is not supposed to have a relay for DRL. It does have a relay for the parking/tail lights/markers.

I am guessing that you are now running with no tails or markers. Not a minor safety issue.

 

Yeah hope he checked that... Those DRL's are one of my favorite features of my 06 and I personally think they look bada$$ rolling down the rode. When you shift into drive they light up. "Thrust Mode, ACTIVATE." lol