I was driving to my family's home on christmas, when my car suddenly began to smell like burnt rubber inside of the car. It was raining on that day. Suddenly the cars ac, or h vac did not work anymore. Upon googling things of what it could be, I found out that the resistor and blower motor had been burnt do to be allowing water to enter the blower motor panel from the outside of the car.…
2006 Chevrolet HHR electrical problems
critical 142 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
142
Recalls
0
Avg fix
$850
5crashes
2fires
6injuries
4fatalities
When does it fail?
Of the 142 electrical complaints filed for the 2006 Chevrolet HHR, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 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
Of the 6 model years of Chevrolet HHR we track for electrical problems, this one carries the most owner complaints on file — 142.
Owners have filed 142 electrical 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.
The failure pattern owners describe
Buyer takeaway: A 2006 Chevy HHR electrical system is a minefield: ignition switches jam keys, engines stall without warning at highway speeds, headlights flicker or go dark completely, and doors mysteriously lock/unlock while driving. Multiple owners faced battery drain, power steering loss, and water intrusion. Many dealers cannot diagnose the problems, and recalls have either left cars unfixed or worsened electrical gremlins. You will find yourself stranded or in danger, and out-of-warranty repairs run into hundreds of dollars.
The 2006 HHR electrical system produces a cascade of failures that service departments struggle to diagnose. The most common problem is the ignition key getting stuck in the switch—owners cannot remove the key even after the engine is shut off and the car is in Park. The cause is a plastic actuator rod in the shifter assembly that cracks and falls out, preventing the solenoid from releasing the lock. GM acknowledged this via Technical Service Bulletin 06-07-30-004F for 2006–2010 HHRs, Cobalts, and Pontiac G5s. The fix is a complete shifter assembly replacement (~$185 plus labor), though many dealers declined warranty coverage after the recall period.
Engine stalling at highway speeds is the second major complaint. Owners report sudden total power loss—lights go out, steering fails, radio dies, and the engine shuts down, often triggered by bumps or potholes. Vehicles restart after 10 minutes to an hour. Service departments have replaced alternators, computers, ignition coils, and ground wires without resolving the issue. One crash occurred when the vehicle stalled and air bags failed to deploy.
Headlights flicker intermittently or fail completely. Dash lights remain too dim in daylight and too bright at night. Bulbs and switches were replaced without fixing the problem. One owner experienced a near head-on collision when headlights went dark. Battery drain accompanies many electrical failures; one owner needed daily jump starts.
Water intrusion causes blower motors and resistors to burn out, producing burnt rubber smells and failed defrost during rain. Door locks fail to engage electronically, and interior door handles crack and break. Post-recall ignition switch installations have introduced new electrical gremlins: security alarms firing without cause, cruise control disabling, and radios stopping. One vehicle's kill switch activated at 65 mph on the highway.
Same Chevrolet HHR electrical reports on nearby years: 2007 · 2008 · 2009
Failure modes owners describe
Key stuck in ignition / failure to release
Ignition lock cylinder fails to release the key from the ignition switch, even when the vehicle is in Park and turned off. The root cause is a plastic actuator rod in the shifter assembly that breaks or falls out, preventing the solenoid from being activated to release the key. Without the manual release button workaround, the key remains trapped and the battery drains.
When: Occurs intermittently or progressively; reported across 2006–2010 model years; one owner reported within first two weeks of purchase; another after 4+ years of ownership
Symptoms owners cite: Key cannot be turned to OFF position; Key cannot be removed from ignition when vehicle is in Park; Battery drains if key left in ignition for extended time (1+ hour); Shift lever moves without pressing shift button; Manual release button under steering column required as workaround
Repairs/costs cited: Shifter assembly replacement costs ~$185 plus labor. Manual release button on underside of steering column used as temporary fix. One owner reported key still stuck after recall ignition switch installation.
Recalls/TSBs owners mention: GM TSB #06-07-30-004F acknowledges common occurrence 2006–2010 HHR, Cobalt, G5. Some dealers reluctant to repair out of warranty. Recall 14V047000 (Air Bags, Electrical System) and 14V171000 (Electrical System) address ignition-related failures.
Engine stalls / total power loss while driving
Vehicle loses all electrical power or engine shuts off completely while driving, typically triggered by road bumps, potholes, or highway joints. Loss of power steering, lights, and instrument cluster. Vehicle restarts after delay (10 minutes to 1+ hour). Occurs intermittently with increasing frequency. Service departments unable to diagnose root cause on multiple visits.
When: Ranges from 8,000 to 148,000 miles; occurs on highways at 50–70 mph; some owners report 4–10 occurrences in single trip
Symptoms owners cite: Engine shuts off completely at highway speed; All lights go out (headlights, dashboard, radio); Power steering fails; Doors lock/unlock erratically before stall; Cruise control disables; Vehicle coasts without power; Restart after 10 minutes to 1+ hour
Codes mentioned: Reduced Engine Power warning, Engine Disabled warning, Check Charge System, Battery Saver mode
Repairs/costs cited: Mechanics have replaced alternator, main computer/cluster module, ground wire, and ignition coils without consistently resolving. One owner reports mechanic replaced main computer and power steering motor at cost over $900. Another was told to 'drive around to dry off electrical system' after water intrusion suspected.
Recalls/TSBs owners mention: Service departments report inability to replicate; some say 'no problem identified.' Recall 14V171000 (Electrical System) and 14V047000 issued but one owner's parts unavailable for months. One vehicle crashed during stall; air bags did not deploy.
Ignition key turns to OFF without resistance / loss of steering lock
Ignition key can be turned to OFF position with minimal or no pressure, particularly after bumping or due to key-ring weight. Allows accidental ignition shutdown while driving at speed. Related to loose or worn ignition cylinder contact.
When: Reported around 70 mph after hitting pothole; occurs intermittently; one owner tested by light handling of keys and confirmed unsafe condition
Symptoms owners cite: Key turns OFF with no pressure or light bumping; Can turn off while driving; Accidental shutdown risk; Steering lock may fail; Shift lever moves without button press
Repairs/costs cited: Requires ignition key cylinder replacement. One dealer unable to replicate when tested.
Recalls/TSBs owners mention: No recall action noted for this specific condition. One owner called dealership seeking lock cylinder that prevents key movement.
Headlight / instrument lighting flickering and failure
Headlights flicker intermittently or fail completely; dash lights dim or fail to illuminate properly. Auto on/off feature malfunctions, causing dash to remain completely dim in daylight or overly bright at night. Headlights go out entirely and come back on after 30+ minutes of driving. Replaced bulbs and switches did not resolve; fuses and wiring tested as normal by dealers.
When: Reported at various mileages; one case required 30+ minutes of driving before headlights returned
Symptoms owners cite: Headlight flicker intermittently; Complete headlight failure with high-beam workaround; Dash lights dim or completely dark in daylight; Dash lights too bright at night; Lights flicker between bright/dim without pattern; High-beam headlights are only consistent source; Battery drains daily
Repairs/costs cited: Replaced headlight/blinker switch, headlight bulbs, battery, and alternator without resolution. Dealers claim all fuses and wiring harness normal but issue persists. One owner reported near head-on collision due to headlights extinguishing.
Recalls/TSBs owners mention: Dealers state fuses and wiring are fine; unable to identify root cause. No recall action noted.
Instrument cluster / gauge failure (speedometer, odometer, tachometer, temperature, oil pressure)
Electronic dashboard gauges (speedometer, odometer, tachometer, temperature, oil pressure) become unresponsive or flicker erratically. Clock and air bag sensors also flicker. Failure occurs randomly with no pattern; resolves after cycling key off and on multiple times. Happens regardless of driving conditions or speed.
When: First occurrence 1 year after purchase at 1,500 miles; recurred intermittently over years; one case at 45,000 miles
Symptoms owners cite: All gauges unresponsive; Speedometer, odometer, tachometer freeze; Temperature gauge and oil pressure gauge non-functional; Digital clock flashes or goes dark; Air bag warning flashes; Headlights and dashboard lights off simultaneously; Radio lights flashing at night randomly
Codes mentioned: Air bag sensor warning
Repairs/costs cited: Dealers replaced electronic control module and other electronic parts without consistent resolution. One owner reports 7 separate service visits; dealer stated owner is 'only one' with this problem despite it occurring multiple times.
Recalls/TSBs owners mention: Dealers unable to locate issue; some claim owner is unique case. Electronic Control Module (ECM) replaced but failure persisted.
Blower motor / HVAC resistor failure (water intrusion)
Blower motor and HVAC resistor burn out or fail due to water intrusion from outside vehicle. Owner reports burnt rubber smell inside car during rain. Defrost motor stops working, preventing windshield demisting. Water leaks into passenger floor board. Burn marks visible on blower motor and resistor components.
When: One case on rainy Christmas day; another case triggered by water entering through blower motor panel
Symptoms owners cite: Burnt rubber smell in cabin; Blower motor and resistor burn out; Defrost / AC stops working; Water leaks into passenger-side floorboard; Reduced visibility from windshield fogging; Screeching noise on fan settings 3–4 before failure
Repairs/costs cited: One case: dealer initially misdiagnosed as A/C blower problem related to car sitting idle. Actual issue was burnt motor requiring replacement. Cost ~$527 for blower motor repair out of warranty. Another case: water evacuation system design allows rain to enter blower motor cavity.
Recalls/TSBs owners mention: GM design flaw documented; water evacuation system below windshield allows rain intrusion. No recall despite safety concern (defrost failure = no windshield visibility).
Door lock actuator failure (electronic)
Electric door lock actuators fail on multiple doors (passenger, rear left, rear right). Doors will not lock or unlock via key fob or door lock switches. One case involved 3 of 4 total door lock actuators failing.
When: Reported at 21,000–27,920 miles; one case involved multiple failures on same vehicle
Symptoms owners cite: Door lock switches inoperative; Key fob does not lock/unlock doors; Doors lock/unlock sporadically while driving; Cannot secure vehicle
Repairs/costs cited: Replacement cost ~$340 per door. One dealer stated no fix available; another had not seen issue before despite 30+ complaints logged online.
Recalls/TSBs owners mention: No recall or warranty extension noted. Dealers claim no fix or deny familiarity with issue.
Door handle fracture (interior)
Interior door handles on driver and passenger sides fracture and break. One owner's driver-side handle broke completely off. Passenger may be unable to exit vehicle; owner became temporarily trapped.
When: Reported at 21,000 and 45,000 miles
Symptoms owners cite: Interior door handle cracks or breaks on exit; Complete detachment of handle; Inability to open door from inside; Temporary entrapment
Repairs/costs cited: Dealer advised entire door replacement needed. One owner's vehicle not repaired; another repair declined due to cost and repeated failures on same vehicle.
Recalls/TSBs owners mention: Dealer states entire door replacement required; no alternative fix offered.
Shift lever stuck in Park / difficult to shift
Automatic transmission shift lever will not release from Park position, or requires multiple cycling through gears (Park to Drive, back to Park) to unlock key and allow vehicle to be driven. Related to shifter actuator rod failure affecting key release solenoid.
When: Reported at various mileages; one case required repeated shifting attempts to free it
Symptoms owners cite: Gear shift locked in Park; Difficult or impossible to shift out of Park; Repeated cycling of gears required to release key; Shift lever moves freely without button press (when actuator rod fails)
Repairs/costs cited: Related to broken plastic actuator rod in shifter assembly. Shifter assembly replacement ~$185 plus labor required.
Recalls/TSBs owners mention: GM TSB #06-07-30-004F documents issue; recall 14V171000 issued for transmission shifter not properly transmitting electrical signal.
Alternator failure / charging system fault
Alternator fails to charge battery, resulting in complete electrical shutdown while driving. Instrument panel displays 'Check Charge System' and 'Battery Saver On' warnings. Vehicle loses all power, including power steering and lights. Replacement alternator required.
When: Reported at 170 miles into trip (post-battery replacement); one case at higher mileage
Symptoms owners cite: 'Check Charge System' message on display; 'Battery Saver On' warning; Battery drains despite new battery installation; Total power loss while driving; Steering lock failure; All systems shut down
Codes mentioned: Check Charge System, Battery Saver mode
Repairs/costs cited: Alternator replacement completed; cost not specified. One owner notes display message should read 'Alternator Failure' for clarity.
Recalls/TSBs owners mention: No specific manufacturer response noted; one owner had to rely on independent mechanic diagnosis.
Electrical short / security system fault (post-ignition recall)
After ignition switch recall service, multiple electrical failures occur: cruise control disables, door locks malfunction, security alarm triggers inappropriately, radio stops working, blinker switch acts erratically, and steering wheel seizes briefly. One owner's security system activated (kill switch) while driving 65 mph, disabling vehicle. System rebooted by independent mechanic without dealer diagnosis.
When: Occurred after recall ignition switch installation; security system kill activation at 128,000 miles
Symptoms owners cite: Cruise control disables intermittently; Door locks lock/unlock erratically; Security alarm sounds without cause; Radio stops or starts randomly; Blinker switch flicks on/off; Key can be removed while vehicle running (post-recall); Steering wheel seizes temporarily; Kill switch activates while driving
Codes mentioned: Theft Deterrent alarm, Power Steering light
Repairs/costs cited: One case: independent mechanic rebooted security system; dealer could not diagnose. One owner bypassed radio by removing fuse to prevent battery drain. Dealer suggested ignition switch replacement had nothing to do with electrical failures post-installation.
Recalls/TSBs owners mention: GM customer service states ignition switch replacement is unrelated to post-installation electrical problems. Recall 14V047000 and 14V171000 issued but fail to resolve recurring failures.
Water leak into cabin (passenger floor, windshield seal)
Water enters passenger-side floorboard during rain. Windshield leak allows water to pool on floor. Water intrusion into electrical components, including blower motor assembly. Defrost inoperative due to water damage.
When: Occurs during rainy conditions
Symptoms owners cite: Passenger floor fills with water during rain; Windshield seal leaks; Water damage to electrical components; Blower motor burns from water exposure; Defrost non-functional
Repairs/costs cited: Windshield replacement performed but seal not properly reinstalled; water continued to leak. One case: blower motor required replacement due to water intrusion burn damage.
Recalls/TSBs owners mention: No recall or design modification noted. GM water evacuation system design flawed (below windshield).
HVAC blower motor resistor failure (electrical, non-water)
Blower motor resistor fails, limiting fan operation to highest setting only. Screeching noise occurs on lower settings before failure. Recurring problem: replaced under warranty but failed again shortly after.
When: First failure July/August 2008; recurred September 2008; owner reports similar issue on 2007 HHR belonging to parents
Symptoms owners cite: Screeching noise on fan settings 3 and 4; Fan only works on highest setting; Cannot control fan speed; Resistor needs replacement
Repairs/costs cited: Resistor replacement cost $300 when out of warranty. Dealer claimed to have replaced resistor under warranty first time but only 'blew out the system.' Recurring failure suggests inadequate initial repair or defective replacement part.
Recalls/TSBs owners mention: Dealer performed warranty service first time; owner advised resistor replacement cost $300 second time despite recurring nature.
Radio / audio system malfunction
Radio display and controls malfunction: radio cannot change stations, turns up to maximum volume and will not decrease, radio stops working entirely, digital clock does not set or function, CD player buttons inoperative, remote start button non-functional.
When: Reported at various mileages; one case after battery drained from stuck key
Symptoms owners cite: Radio cannot change stations; Volume stuck at maximum; Radio turns off entirely; Digital clock non-functional; CD player buttons non-responsive; Remote start non-functional; Radio turns on by itself
Repairs/costs cited: Dealer ordered replacement radio; not yet installed in one case. Another case: radio functions intermittently and stopped working after key stuck in ignition event and battery drained.
Recalls/TSBs owners mention: Dealer ordered replacement radio; no broader investigation noted.
Fuel gauge fluctuation / instrument panel erratic behavior
Fuel gauge fluctuates rapidly; instrument panel lights illuminate erratically with abnormal noise. Engine surges. Vehicle shuts off and restarts after delay, resuming normal operation.
When: Reported at 20 mph, 45,000 miles; recurred numerous times
Symptoms owners cite: Fuel gauge fluctuates rapidly; Abnormal noise from engine bay; Instrument panel lights flash erratically; Engine surge; Vehicle stalls then restarts
Repairs/costs cited: Dealer unable to determine remedy; vehicle not repaired.
Recalls/TSBs owners mention: No diagnosis provided.
Battery drain / repeated dead battery
Battery drains repeatedly despite replacement. Vehicle requires daily jump starts. Related to ignition switch left in ON position, electrical shorts, or blower motor/radio staying powered.
When: Occurs after key stuck in ignition; also with headlight flickering issues and blower motor problems
Symptoms owners cite: Battery dies after key left in ignition; Repeated dead batteries despite replacement; Requires daily jump starts; Battery overheats during charging
Repairs/costs cited: Battery replaced; problem persisted with alternator and/or ignition switch issues. One mechanic found battery 'very hot' indicating electrical overload.
Recalls/TSBs owners mention: Dealer advised battery replacement; did not investigate underlying cause (ignition switch or shorts).
Reduced Engine Power warning / limp mode
Dashboard displays 'Reduced Engine Power' message, limiting vehicle to 30 mph. Occurs intermittently; may be related to ignition switch or electrical sensor failures.
When: Reported on dry roads; occurs intermittently, sometimes weekly
Symptoms owners cite: 'Reduced Engine Power' warning on dash; Vehicle limited to 30 mph; Unable to accelerate normally; Recurs without pattern
Codes mentioned: Reduced Engine Power
Repairs/costs cited: Dealers unable to diagnose when not actively occurring; advised owner to bring vehicle in during failure.
Recalls/TSBs owners mention: No solution provided.
Power steering failure / steering wheel seizure
Power steering cuts out completely, requiring significant force to turn steering wheel. Vehicle becomes difficult to control. Steering wheel seizes temporarily. Power Steering warning light illuminates. Problem worse on highways; one owner's cost over $900 to replace power steering motor and main computer.
When: Reported at 65–70 mph on highway; one case at 85,000 miles
Symptoms owners cite: Power steering suddenly fails; Steering wheel requires excessive force; Power Steering warning light; Steering wheel seizes temporarily; Difficult vehicle control, especially at highway speeds
Codes mentioned: Power Steering warning light
Repairs/costs cited: One case required replacement of power steering motor and main computer costing over $900. Another case: mechanic diagnosed faulty ignition coil and module, replaced.
Recalls/TSBs owners mention: GM issued recall in Canada but not USA, despite same power steering motor used on other Chevy models that received recall.
Synthesized from 142 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Contact reported that door locks would not operate with key fob nor when activating the door lock switches on the door. Took vehicle to two different dealers trying to get the ignition recall fixed which took a total of four visits. While car was in for recall, addressed an unrelated electrical solenoid problem and asked the dealer to look at the door lock issue. Dealer notified owner that…
Key locks in the ignition and will not release, it took repeated attemps at first of cycling the key off and on to get it to release after a week or two the proplem became worse to the point of the the shifter had to be cycled from park to low and back several times before the key would lock and release from the steering collum, after a few days this didn't work,the problem then was mentioned to…
Had electrical 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 electrical problem on the 2006 Chevrolet HHR?
It's a serious issue. 142 complaints have been filed, including 5 reports involving a crash and 4 fatality(ies). We've classified it as critical based on NHTSA's reported outcomes.
At what mileage does the electrical typically fail?
Across the 102 complaints that reported odometer mileage, most electrical failures cluster between 29,000 and 125,000 miles, with the median around 73,189. A quarter of owners report trouble before 29,000; a quarter make it past 125,000. 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 $850 for electrical 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 electrical?
No active recalls currently cover electrical 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.