This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
full bulletin at NHTSA ↗2006 Chevrolet HHR body problems
moderate 93 complaints filed with NHTSA · avg repair $1,500 · see body across all vehicles →
Failure mileage
Complaints
93
Recalls
0
Avg fix
$1,500
1crash
What stands out
Of the 6 model years of Chevrolet HHR we track for body problems, this one carries the most owner complaints on file — 93.
Owners have filed 93 body complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body 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 Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about vehicles that have a loud tick or rattle noise under the hood at all operating conditions. Technician will need to check the lower and oil pressure to the upper end oil pressure. Technician will need to inspect the oil feed orifice in the cylinder head. Technician will clean out and debris found in the orifice.
full bulletin at NHTSA ↗THIS PRELIMINARY INFORMATION COMMUNICATION ADVISES THE TECHNICIAN THE STEPS ON DIAGNOSING THE CONCERN. VEHICLE'S SUNROOF OPERATION INTERMITTENT, BIND, NOISE, AUTO-REVERSE, AND/OR WATER LEAKS.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about vibration complaints that are one of the most challenging complaints to accurately diagnose and repair. Technician will need to use Pico Oscilloscope Diagnostic Kit to effectively diagnosis vehicles. Technician should drive the vehicle will using the Pico Oscilloscope to record data. After the data is recorded it should be reviewed to determine the root cause of the concern. If a repair attempt made the concern better but not eliminated or had no affect at all, and are requesting assistance from General Motors Technical Assistance Center record another Pico file and save it to the computer. After the new
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 HHR has a pattern of plastic interior door handles breaking during normal use—most commonly on the driver side, often within 3–5 years or between 25,000 and 95,000 miles. Owners pull the handle to open the door and it fractures, sometimes in their hand. A handful report the handle breaks a second time after replacing the entire door panel (the only repair option Chevy offers, costing $300–$600 with labor). When the handle fails, occupants must roll down the electric window and use the outside handle to exit—a genuine safety issue if the electrical system is compromised after an accident or if the battery dies. Multiple owners have been locked in their vehicles because the door handle broke and the window or locks wouldn't function without power.
Water leaks into cabins through the windshield frame and heater ductwork, pooling on floorboards and creating mold problems. One owner saw rust on the rear bumper support at just 52,000 miles and one year of ownership—a manufacturing defect in an unprotected steel component.
Owners across multiple reports note that Chevy either denies the problem exists or refuses to address it through recalls or service programs. Dealerships report the failures are "common issues" but do not offer solutions. Third-party suppliers online sell individual replacement handles because so many owners need them, but Chevy will not.
Same Chevrolet HHR body reports on nearby years: 2007 · 2009
Failure modes owners describe
Interior door handle fracture/breakage
Plastic interior door handles on driver and/or passenger sides fracture, break off, or fail during normal opening operation. The handles are integrated into the door panel assembly and cannot be replaced separately. When broken, occupants must roll down the window and use the exterior handle to exit, creating a serious safety concern if power windows fail (e.g., after an accident or electrical failure).
When: Typically between 25,000–95,000 miles, often within 3–5 years of ownership; some failures occur as early as 36,400 miles and recur at similar mileage intervals on replacement panels.
Symptoms owners cite: Plastic handle breaks off or fractures during normal door opening; Handle feels soft or stuck before failure; Handle breaks a second time after replacement (using same design); Door cannot be opened from inside without rolling down electric window; Occupants trapped or severely inconvenienced if window or electrical system fails
Repairs/costs cited: Dealers require replacement of the entire interior door panel ($300–$600 per panel with labor) because Chevy does not sell the handle separately. Third-party suppliers sell individual replacement handles online; some owners report dealers initially claim no parts are available or parts are on national backorder. One owner paid for repair under warranty at ~36,400 miles; handle broke again at ~72,400 miles on the replacement panel.
Recalls/TSBs owners mention: GM claims to have never received complaints about this issue (contradicted by multiple complaints in cluster). One owner reports manufacturer offered to cover 25% of repair costs. Dealers typically state the failure is a 'common issue' but offer no recalls or service bulletins. No formal manufacturer support documented.
Rear bumper support corrosion
Rear bumper support is made of unprotected steel rather than aluminum. Water collects under the bumper cover and sits on the steel support, causing rapid rust formation at very low mileage. A collision center identified this as a manufacturing defect; the design allows water infiltration with no drainage.
When: At or very early in vehicle life; one owner reported rust at 52,000 miles, vehicle less than 1 year old and pre-first-service.
Symptoms owners cite: Visible rust on rear bumper support within first year of ownership; Water accumulation under bumper cover; Rust spreads progressively; described as 'like cancer'; Structural integrity compromised at a major crash-protection component
Repairs/costs cited: One collision center (Hayes Collision, Sacramento, CA) identified as manufacturing defect. Dealer wanted $112 to inspect. No cost for repair documented; owner unable to afford fix.
Recalls/TSBs owners mention: GMAC Customer Care Center contacted; neither GMAC nor dealer (Mike Daugherty Chevrolet, Sacramento) took responsibility. Collision center recommended aluminum construction instead of steel; no manufacturer response to this recommendation documented.
Door latch mechanism failure
Front door latches fail to operate, preventing the door from opening from either interior or exterior handle. The latch remains physically intact but the mechanical connection breaks or seizes.
When: Documented at 113,000 miles and 80,000 miles; one complaint also mentions rear hatch door latch failure within 6 months of ownership.
Symptoms owners cite: Door will not open from inside or outside handle (latch stuck/broken); Door may sporadically open while driving at low speed (5–10 mph) before becoming stuck closed; Handle feels normal but latch does not release
Repairs/costs cited: Dealers report plastic part inside panel needs replacement; no specific parts cost or labor documented. One complaint links latch failure to low-quality plastic molding.
Recalls/TSBs owners mention: No manufacturer response documented.
Water intrusion into cabin (windshield and heater/dashboard area)
Water leaks into the vehicle from multiple points: windshield frame, heater ducts, and the seal around the heater switch. Water accumulates on floorboards, causing soaking and mold/mildew growth. One case involved the computer board becoming wet.
When: Documented from 18,300 miles through 50,000 miles; one owner first noticed in August 2009, issue became recurring after initial occurrence.
Symptoms owners cite: Water accumulation on front passenger and driver-side floorboards after rain; Up to 2 inches of standing water on floor after heavy rain; Mold and mildew odor/growth developing in carpet; Heater motor malfunction (only one speed operation) after water entry through heater switch seal; Computer board corrosion from windshield leak
Repairs/costs cited: Dealer recommendations include carpet replacement (to prevent mold spread). Heater switch seal repair and heater unit replacement documented in one case (~45,000 miles). One owner reported out-of-warranty diagnosis cost estimated to be high; insurance company would not cover due to no windshield damage.
Recalls/TSBs owners mention: No recalls or service bulletins mentioned; owner advised to bring to dealer but warranty had expired. Manufacturer response not documented in most cases.
Door hinge structural failure / excessive door opening
Under moderate wind conditions, a car door opens far beyond its normal range (nearly 180 degrees) and jams, leaving the door open only 16–18 inches. The quarter panel sustains damage and deformation, creating a gap that the door now rubs against.
When: Documented at one vehicle; occurred during parked conditions in 20–30 mph winds.
Symptoms owners cite: Door swings open excessively under wind pressure; Door cannot be closed fully; opens only 16–18 inches; Quarter panel visibly deformed/pushed outward (4 inches); Door rubs hard against quarter panel; Owner suspects defective or loose hinges
Repairs/costs cited: Owner estimated ~$2,000 in repair costs pending insurance adjuster estimate.
Recalls/TSBs owners mention: No manufacturer response documented.
Rear rocker panel paint damage / surface erosion
Protective plastic guards on rear rocker panels are sandblasted and eroded during normal highway driving on paved roads, exposing the paint underneath. Paint then peels off. Dealer initially claimed guards are designed to take this abuse, then repainted and installed mudflaps at their cost. Paint erosion recurred after mudflap installation.
When: Documented over extended ownership period; initial damage visible after normal driving, recurrence after mudflap installation.
Symptoms owners cite: Sandblasting/erosion of rear rocker panel guards during highway driving; Paint peeling from underlying surface; Damage continues despite mudflap installation
Repairs/costs cited: Dealer initially repainted and installed mudflaps at their cost. After erosion recurred, dealer offered 50% cost-share for running boards (~additional protective trim). Owner paid remaining balance.
Recalls/TSBs owners mention: GM Business Resource Center denied responsibility, claiming owner should have purchased running boards at time of sale. Ultimately dealer agreed to 50% subsidy for running boards.
Synthesized from 93 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Drivers side door handle broke off when getting out of vehicle. Dealer will not repair unless I pay for the repair. This is a safety hazard because you cannot exit the vehicle unless you let the window down. *tr
Had body trouble with your 2006 Chevrolet HHR?
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 body problem on the 2006 Chevrolet HHR?
It's a documented issue but not catastrophic. 93 complaints have been filed. Repairs average $1,500 and most owners catch it before it causes a breakdown.
At what mileage does the body typically fail?
Across the 78 complaints that reported odometer mileage, most body failures cluster between 45,000 and 88,000 miles, with the median around 68,000. A quarter of owners report trouble before 45,000; a quarter make it past 88,000. 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 $1,500 for body 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 body?
No active recalls currently cover body 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/HHR.
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.