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 Cobalt lighting problems
severe 12 complaints filed with NHTSA · avg repair $250 · see lighting across all vehicles →
Complaints
12
Recalls
0
Avg fix
$250
1crash
1injury
When does it fail?
Of the 12 lighting complaints filed for the 2006 Chevrolet Cobalt, here's the actual mileage breakdown — failures cluster heaviest at 125,000-150,000 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
Among the 5 model years of Chevrolet Cobalt in our records for lighting problems, this one ranks #2 by owner-complaint volume.
No new NHTSA lighting complaint has been filed on this vehicle in over 9 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 a pattern of lighting failures across multiple systems. Headlight circuits melt internally, causing repeated bulb blowouts and complete loss of function; one owner was without lights for four months. Turn signal switches fail mid-drive and won't self-cancel, with dealership replacement not solving the issue. Rear turn signal bulbs overheat, with plastic melting at the connection point to metal contacts—a fire hazard.
Dashboard instrumentation lights refuse to work when headlights are switched to manual mode, only illuminating with the automatic system active. This leaves drivers unable to see the speedometer in dim or overcast conditions—a real safety problem. One owner reports brake lights stuck on, requiring manual pedal manipulation to extinguish them.
Headlight glare is excessive enough that owners report blinding other drivers and pedestrians. One complaint also mentions airbags that failed to deploy in frontal crashes, with GM issuing a recall warning for 2005–2007 model years. Repair costs for wiring replacement alone ran to $700, and some owners couldn't get dealerships to cover defects not on their specific VIN despite others having recalls for the same problems.
Same Chevrolet Cobalt lighting reports on nearby years: 2005 · 2008
Failure modes owners describe
Headlight wiring melt and bulb failure
Complete failure of headlight circuit due to internal wiring melting inside the headlight assembly. Bulbs blow repeatedly, then one side stops working entirely. Melted liquid observed running from bulbs and damaged wiring. Turn signals also fail as a result. Requires replacement of both headlamp units and wiring harness.
When: 4 months of non-function reported; complaint filed after extended bulb blowouts
Symptoms owners cite: Repeated headlight bulb failure; One headlight stops working, then both fail; Melted liquid visible inside headlight shields; Turn signals stop working; Bulb shields no longer hold assembly together
Repairs/costs cited: Chevrolet dealer quoted $700 for replacement of both headlamp units and wiring harness including battery connection wire. Owner reports knowing 2005 model had recall on headlights with same defective parts.
Recalls/TSBs owners mention: 2005 model year headlight recall mentioned but unknown if applied to 2006 model
Turn signal switch failure and cancellation issues
Turn signal switch stops functioning or fails to self-cancel after turns. Multiple instances of switch clicking ceasing mid-drive, and right turn signals failing to cancel consistently despite different steering wheel angles. Dealership replacement of switch does not resolve issue.
When: While driving at 30 mph; reported since vehicle was new in one case
Symptoms owners cite: Turn signal switch stops working completely; Clicking sound for turn signals ceases; Turn signal fails to auto-cancel after right turns; Turn signal cancellation inconsistent
Repairs/costs cited: Dealership replaced turn signal switch once without resolving the problem. No repair cost reported.
Rear turn signal bulb overheating and melting
Rear blinker bulb burns out prematurely, and when replaced with manufacturer-specified bulb, the plastic on the replacement bulb melts at the connection point to the metal contacts. Plastic melts onto the metal contacts, creating fire hazard. Issue occurs within weeks of bulb replacement.
When: Replacement bulb installed December 2016; failed by December 26, 2016
Symptoms owners cite: Rear blinker bulb burns out; Replacement bulb melts at connection point; Plastic melts onto metal contacts; Fire hazard condition created
Repairs/costs cited: Sylvania 3157 LL Long Life replacement bulb specified for 2006 Cobalt; burned/melted at connection. Multiple owners report same issue online.
Instrument panel lights inoperative in manual mode
Dashboard instrumentation lights fail to illuminate when headlights are switched to manual position. Lights only work when automatic lighting system is activated. Creates safety hazard in cloudy or foggy conditions when manual headlights are needed but automatic sensor does not trigger, leaving driver unable to read gauges and speedometer.
When: Reported when switching from automatic to manual headlight mode
Symptoms owners cite: Dashboard lights do not illuminate in manual headlight mode; Dashboard lights only work with automatic lighting system; Unable to see speedometer and gauge cluster in dim conditions; Speedometer visibility compromised in cloudy/foggy weather
Recalls/TSBs owners mention: No manufacturer response documented; complaint noted as potentially violating FMVSS 101
Brake light switch malfunction
Brake lights remain illuminated after brake pedal is released. Requires manually lifting the brake pedal slightly to turn off lights. No warning to driver that lights are stuck on. Manufacturer unable to fix the problem.
When: Recurring issue on regular basis, approximately once per day
Symptoms owners cite: Brake lights stay on when brake pedal released; Lights only turn off when brake pedal is manually lifted slightly; No dashboard warning of malfunction
Recalls/TSBs owners mention: Manufacturer unable to fix the problem per owner report
Excessive headlight glare and misalignment
Headlights produce excessive glare that blinds other drivers and pedestrians. Lights are overly bright and misadjusted by design, creating safety risk. Issue affects all Cobalt coupe and sedan models (LS, LT, SS trims). Causes distraction, eye strain, and obstruction of road hazards for other motorists.
Symptoms owners cite: Excessive glare from headlights; Headlights blind other vehicles and pedestrians; Misadjusted lighting by design; Creates safety risk for other drivers
Airbag non-deployment in frontal crashes
Airbags failed to deploy in two separate frontal crashes on 2006 and 2008 Cobalt models despite head-on impacts to front bumper. Owner received GM warning letter regarding 2005-2007 model year airbag defect. Vehicles suffered significant damage; driver safety was compromised.
When: June 2010 and February 2011 crashes
Symptoms owners cite: Airbags did not deploy in frontal crash; Front bumper impact did not trigger airbag system
Repairs/costs cited: Maroone Collision Center charged $4,183.16 for repairs to one vehicle after airbag failure. Insurance liability dispute and premium increase resulted.
Recalls/TSBs owners mention: GM issued warning letter about airbag defect in 2005-2007 model year Cobalts noting possible non-deployment
Synthesized from 12 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
On september 19th, 2016 I bought a new two pack of sylvania 3157 ll long life lamps from wal-mart and used one to replace my old left rear blinker light which had burned out. The lights are specified as valid replacement lights for the 2006 Chevy cobalt. On december 26th, 2016 I noticed that the same left rear blinker light was not working again. On december 27th, 2016 I again attempted to…
Had lighting trouble with your 2006 Chevrolet Cobalt?
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 Cobalt?
It's a meaningful issue. 12 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $250.
At what mileage does the lighting typically fail?
Based on the 12 complaints filed, lighting issues most often appear around 85,990 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
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/Cobalt.
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.