This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage.
full bulletin at NHTSA ↗2006 Chevrolet Aveo lighting problems
severe 15 complaints filed with NHTSA · avg repair $250 · see lighting across all vehicles →
Failure mileage
Complaints
15
Recalls
0
Avg fix
$250
3fires
When does it fail?
Of the 15 lighting complaints filed for the 2006 Chevrolet Aveo, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA lighting complaint has been filed on this vehicle in over 11 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering lighting on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This service bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Water Leaks and Replacement Guidelines.
full bulletin at NHTSA ↗This service bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Water Leaks and Replacement Guidelines.
full bulletin at NHTSA ↗This informational bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Replacement Guidelines.
full bulletin at NHTSA ↗This informational bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Replacement Guidelines.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report frequent headlight bulb failures beginning around two years of ownership, recurring every month or two for years. Both headlamp connectors become charred and arced. Dealers and independent mechanics identify an electrical short but cannot locate it without extensive disassembly. After receiving the recall letter (Campaign 14V261000, July 2014), headlights dim so severely that parking lights provide more illumination.
Daytime running lamps fail to activate or flicker sporadically on many vehicles. Owners report visible melting inside the light housings. The recall parts—specifically a replacement headlamp switch—remain unavailable; GM told owners in January 2015 it could not find a vendor to manufacture them. One owner reports the DRL failure recurred even after an attempted repair under the recall.
Multiple owners smell burning odors from the vehicle or see smoke entering the cabin. One vehicle caught fire while parked around 200,000 miles, shortly after the owner observed smoke from the dashboard. The fire department extinguished it; the vehicle was destroyed and no injuries occurred. Dealers acknowledge the recall applies but say repair parts are indefinitely on back order, leaving owners unable to get the vehicle fixed despite a safety recall being open.
Same Chevrolet Aveo lighting reports on nearby years: 2005 · 2007 · 2008
Failure modes owners describe
Headlight premature failure and electrical arcing
Headlights burn out far more frequently than normal, with charred/arced connectors at the bulb plugs. Dealers and independent mechanics identify an electrical short but cannot pinpoint exact location without extensive teardown. After recall letter issued, headlights dim severely—parking lights provide more illumination than headlights.
When: Begins around 2 years of ownership; recurs every 1–2 months over 3+ years
Symptoms owners cite: Headlight bulbs burn out frequently (every 1–2 months); Charred/burned headlamp plugs; Severe dimming of both headlights after recall notice; Parking lights brighter than headlights
Repairs/costs cited: Multiple dealer visits; mechanics unable to locate short without full disassembly. No repair completed.
Recalls/TSBs owners mention: NHTSA Campaign 14V261000 (Exterior Lighting); dealer stated no fix available at time of appointment.
Daytime running lamp (DRL) intermittent failure and melting
DRL lights fail to activate or illuminate sporadically. Physical inspection reveals melted plastic/components inside the light housing. Multiple owners report parts on back order or permanently unavailable. One vehicle had recurrent failure even after attempted repair under recall.
When: Failures reported between 49,000 and 170,000 miles
Symptoms owners cite: DRL fails to activate; DRL activates intermittently or sporadically; Visible melting of light components; Recurrent failure after attempted recall repair
Repairs/costs cited: DRL module diagnosed as needing repair; parts consistently on back order. One vehicle attempted repair under recall; failure recurred at 49,000 miles.
Recalls/TSBs owners mention: NHTSA Campaign 14V261000 (Exterior Lighting/Lighting, Electrical); parts unavailable for repair. GM stated unable to find vendor to manufacture replacement headlamp switch.
Burning smell and smoke from dashboard/lighting system
Owners report acrid burning odor from the vehicle and/or smoke entering cabin through vents, indicating overheating or arcing in the lighting electrical system. One vehicle caught fire while parked shortly after smoke was observed from the dashboard; fire department extinguished it and filed a report. Vehicle was destroyed.
When: Burning smell reported at 115,000 miles; fire occurred at approximately 200,000 miles
Symptoms owners cite: Burning smell inside and around vehicle; Smoke entering cabin through vents, impairing visibility at highway speed; Smoke observed emanating from dashboard; Vehicle fire
Repairs/costs cited: Vehicle taken to dealer; technician identified vehicle was under recall 14V261000 but did not repair. Fire vehicle was total loss.
Recalls/TSBs owners mention: NHTSA Campaign 14V261000 (Exterior Lighting); vehicle included in recall but parts unavailable. No preventive repair performed before fire event.
Abnormal turn signal flashing and emergency brake light interaction
Right turn signal flashes abnormally fast. Headlight fails to illuminate when emergency brakes are applied, suggesting wiring faults between the brake system and lighting circuit.
When: At 68,000 miles
Symptoms owners cite: Right turn signal flashes abnormally fast when turning right; Headlight does not illuminate when emergency brakes applied
Recalls/TSBs owners mention: Vehicle included in NHTSA Campaign 14V261000 (Exterior Lighting); remedy not yet available.
Synthesized from 15 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Tl* the contact owns a 2006 Chevrolet aveo. The contact received a notification of NHTSA campaign id number: 14v261000 (exterior lighting) and stated that the part was not available for several months. The dealer did not give a specific date for when the part would become available. The manufacturer was notified of the delay. The contact did not experience a failure. Updated 02/04/15*lj…
Received letter stating vehicle was being included in a safety recall for the daytime running lights. Letter stated that parts were not currently available and another letter would be sent out when they did become available. Have not heard anything about parts becoming available or any other news at all. So far I have had no issues but am concerned that nothing is being done to fix this problem.…
Tl* the contact owns a 2006 Chevrolet aveo. The contact stated that the daytime running lamps failed. The vehicle was taken to the dealer and the manufacturer was made aware of the failure. The vehicle was not repaired. The failure mileage was 50,000 and the current mileage was 83,000. Updated 02/11/14*lj updated 02/11/14
Had lighting trouble with your 2006 Chevrolet Aveo?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the lighting problem on the 2006 Chevrolet Aveo?
It's a meaningful issue. 15 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $250.
At what mileage does the lighting typically fail?
Across the 10 complaints that reported odometer mileage, most lighting failures cluster between 50,000 and 130,000 miles, with the median around 110,000. A quarter of owners report trouble before 50,000; a quarter make it past 130,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $250 for lighting repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to lighting?
No active recalls currently cover lighting issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Chevrolet/Aveo.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.