This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
full bulletin at NHTSA ↗2009 Chevrolet HHR electrical problems
severe 117 complaints filed with NHTSA · avg repair $850 · see electrical across all vehicles →
Failure mileage
Complaints
117
Recalls
0
Avg fix
$850
1crash
5fires
3injuries
When does it fail?
Of the 117 electrical complaints filed for the 2009 Chevrolet HHR, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 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
Owners have filed 117 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.
Among the 6 model years of Chevrolet HHR in our records for electrical problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering electrical 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 intermittent no crank, no start, or start stall concern with the security light coming on. Technician may find Diagnostic Trouble Codes B3055, B3060, and/or B3935. Technician should not replace any parts for this concern. If unable to duplicate the concern ask if the customer uses any Radio Frequency Identification Devices when the concern is present. Dealer should also direct their customers to the appropriate section in the Owner manuals that references that the device complies.
full bulletin at NHTSA ↗Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.
full bulletin at NHTSA ↗This Preliminary information communicates to the dealer an issue where the vehicle's engine may crank over unprompted and not start afterward. This is the result of hooking up the Active Fuel Injector Tool incorrectly on vehicles equipped with a direct fuel injection system. This Preliminary information instructs the dealer of a repair kit they received that will prevent this issue when installed correctly.
full bulletin at NHTSA ↗This bulletin provides information on identifying Non-GM Engine Calibrations for Gasoline Engines using the Tech 2 or GDS 2.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2009 Chevy HHR shows a pattern of electrical gremlins that catch owners off guard and drain wallets fast. The worst offender is the ignition lock cylinder binding up—key gets stuck in the ON position and won't turn off. Owners routinely report disconnecting the battery or pulling fuses to kill the engine, then paying $300–$400 to replace the ignition cylinder at a dealer. GM sent a service bulletin downplaying it as "sticks or binds," but owners say it's worse: the key locks solid in RUN mode and the engine won't shut down.
The SERVICE AIR BAG light is another chronic complaint. It pops on intermittently, stays off for days, then returns without warning. Dealers have replaced connectors ($17–$265 in parts), sensors, and wiring harnesses multiple times—on the same car—only to see the light come back. Some owners refused GM's lemon-law buyback because the manufacturer claimed it was "fixed," even though it wasn't.
Electrical surges cause tail lights to crack, melt, and burn out every 3–4 days. Backup lights fail repeatedly (one owner replaced 15 bulbs in three years). Power windows and door locks fail. One owner reported brake lights illuminating without brake input, disabling stability and traction control. Two vehicles caught fire—one from the dashboard during A/C operation, another from the center console with the doors locked and ignition stuck. Both burned to the frame.
Recalls exist (14V047000, 14V171000, 14E021000) but parts availability is spotty, and many owners' VINs aren't included in the campaign even though they have identical symptoms. Dealers sometimes can't replicate intermittent faults and refuse to fix them, leaving owners stranded with warning lights and safety systems disabled.
Same Chevrolet HHR electrical reports on nearby years: 2006 · 2007 · 2008 · 2010 · 2011
Failure modes owners describe
Stuck Ignition Key / Inability to Turn Off Engine
Key becomes stuck in the ignition cylinder and will not turn to the OFF position, leaving the engine running. In most cases, owners had to disconnect the battery or pull fuses to shut the engine down. The ignition lock cylinder requires replacement.
When: Throughout ownership; reported at 15,000 to 75,000+ miles
Symptoms owners cite: Key locked in ON position or RUN mode; Engine will not shut off; Key cannot be removed from ignition; Key will not turn backward to OFF position; Engine runs until battery dies or fuse is pulled
Codes mentioned: Ignition lock cylinder failure, Internal cylinder binding
Repairs/costs cited: Ignition lock cylinder replacement; dealers quoted $300–$400 for labor and parts. Some owners had to disconnect battery and fuel pump fuse as temporary workaround.
Recalls/TSBs owners mention: GM issued Service Bulletin (not a recall initially) describing 'some customers may comment that ignition key is difficult to remove or that the key sticks or binds'; later NHTSA recalls 14V171000 and 14V047000 addressed some units but many owners not included in campaigns or had difficulty scheduling service.
Service Air Bag Warning Light (Intermittent or Persistent)
SERVICE AIR BAG warning light illuminates intermittently or stays on continuously without a clear trigger. Light may turn on and off unpredictably during driving. Multiple dealer visits and component replacements (connectors, sensors, wiring) have not resolved the issue for many owners.
When: Intermittent, occurring from early ownership to later years; reported at 9,000+ miles
Symptoms owners cite: SERVICE AIR BAG light comes on intermittently; Light may flash on and off within seconds; Warning light appears during acceleration or with 12V accessory use; Light may come on with or without passengers in front seat; No actual air bag malfunction or deployment
Codes mentioned: Air bag sensor fault, Faulty connector/wiring at front passenger seat, BCM (Body Control Module) communication loss
Repairs/costs cited: Dealers have replaced faulty connectors ($17.28–$264.59 in parts alone), sensors, wiring harnesses, and reprogrammed key fobs. Some technicians suggested RF interference from 12V accessories may be a factor. Despite multiple repairs, light often returns.
Recalls/TSBs owners mention: Some vehicles covered under NHTSA Campaign 14V047000 (Air Bags, Electrical System), but many owners report GM denied coverage or recall inclusion. Dealers offered temporary fixes like disabling 12V accessories but did not resolve root cause.
Brake Light / Electrical Surges (Tail Light Malfunction)
Faulty wiring causes brake lights to illuminate without touching the brake pedal and remain on while driving. This triggers the BCM to lose communication with the brake positioning sensor, disabling electronic stability control, traction control, and panic braking assist.
When: Reported in 2014; failure mileage around 196,000
Symptoms owners cite: Brake lights illuminate without brake pedal input; Brake lights remain on while driving; Electronic stability control disabled; Traction control disabled; Panic braking assist disabled; Cruise control disabled; Electrical surges and power fluctuations throughout vehicle
Codes mentioned: Faulty tail light wiring, BCM loss of communication with brake positioning sensor
Repairs/costs cited: GM dealership performed BCM relearn procedure for brake positioning sensor, which provided temporary relief (~2 months) but required repeat service. Owner noted $95+ towing fee and cannot sustain repeated repairs.
Recalls/TSBs owners mention: GM acknowledged hundreds of complaints and 13 accidents associated with this fault (as of 2014) under May 15, 2014 bulletin; owner filed complaints with NHTSA, FTC, and state consumer protection agency but repair not completed.
Electrical System Faults / Power Surges and Component Failures
Recurring electrical surges and power fluctuations throughout the vehicle cause multiple downstream failures: tail lights crack and melt, backup lights repeatedly burn out, power window switches overheat and smell like burning, and other electrical components fail intermittently.
When: Ongoing throughout ownership; reported over 1+ year periods
Symptoms owners cite: Power/electrical surges occurring at random times; Left rear tail lights burn out, crack, and melt every 3–4 days; Bulb holder melts; Backup lights fail repeatedly (15+ bulbs replaced in 3 years); Power window switches burn and fail; Passenger seat belt locks up; Windows stop operating intermittently; All dashboard gauges fluctuate; All service indicator lights illuminate
Codes mentioned: Electrical system short/fault, Fuse box internal short
Repairs/costs cited: Main fuse box requires replacement; one owner quoted over $600 for repair. Electrical wiring harness replacement also attempted. Dealers unable to isolate root cause.
Recalls/TSBs owners mention: Dealer confirmed recall exists for electrical system on some HHRs but owner's VIN not included. GM headquarters informed owner repair not covered under warranty and issue is owner's responsibility.
Electronic Control Panel / Dashboard Failures
Front driver-side electronic control panel fails; front and rear window controls stop working electronically. Climate control (HVAC) also fails. Issues worsen in rainy weather. One vehicle experienced smoke and fire near dashboard during air conditioning operation.
When: Reported at 51,000–196,000 miles
Symptoms owners cite: Electronic window controls inoperative; HVAC vent controls fail to work; Failures worsen during rain; Smoke emitted from dashboard near vents; Vehicle fire erupted from dashboard area
Codes mentioned: Parts unavailable for NHTSA campaigns 14V047000, 14V153000, 14V171000
Repairs/costs cited: One vehicle was total loss due to fire; another required parts that were unavailable. Dealer unable to complete recall repairs due to parts scarcity.
Recalls/TSBs owners mention: NHTSA campaigns 14V047000, 14V153000, and 14V171000 identified but parts not available; no remedy provided to owner whose vehicle burned.
Ignition Switch / Engine Stalling and Cranking Faults
Engine stalls intermittently while driving or fails to crank. Key cannot be turned to start position or ignition switch binds. Some vehicles produce error codes pointing to ignition and starter units but mechanics find no actual defect.
When: Early ownership; reported at 40,000–50,000 miles and 15,254–26,000 miles
Symptoms owners cite: Engine stalls at various speeds; Engine will not crank or turn over; Key stuck or unable to turn to start position; Abnormal clicking sound when attempting start; Vehicle starts then immediately shuts off; Internal cylinder failure
Codes mentioned: Ignition/starter error codes, Power train relay open, Loss of communication with BCM due to internal short
Repairs/costs cited: Dealers replaced starter, ignition switch, power train relay, and BCM; one vehicle towed to shop where no defect could be found and codes were cleared.
Recalls/TSBs owners mention: NHTSA recalls 14V171000 and 14E021000 exist but repair availability delayed; one owner's vehicle diagnosed with internal cylinder failure outside warranty; no coverage offered.
Power Steering Loss (Electronic Power Steering Pump Failure)
Electrical power steering pump fails suddenly while driving at highway speed. Steering becomes extremely difficult (like manual steering with no power assist). Problem recurs after brief rest. Dealer confirms only they can repair the electronic power steering pump.
When: Reported in late 2010 at highway speed
Symptoms owners cite: Steering wheel becomes very hard to turn; Loss of power steering assist; Steering feels like manual steering; Problem repeats after resting 5 minutes; Unable to find power steering fluid reservoir
Codes mentioned: Electrical power steering pump failure
Repairs/costs cited: Owner reported this is dealer-only repair and anticipated high cost. Vehicle sat in driveway awaiting repair funds.
Recalls/TSBs owners mention: No recall issued for HHR (though Cobalt had similar recall). Owner found numerous online complaints about same issue in both Cobalt and HHR despite being same platform.
Instrument Cluster / Headlight Intermittent Failure
Headlights, interior lights, and instrument panel lights dim, flicker, or go completely out intermittently. Problem worsens or occurs during rain. Lights return on after ignition restart or on their own. One vehicle crashed into from rear due to dimmed lights.
When: Intermittent, occurring during dark morning commute; failure at 51,000 miles
Symptoms owners cite: Headlights dim or go completely out while driving; Interior lights on instruments and radio dim or go out; Lights flicker and pop back on randomly; Problem worse in rain; Restarting ignition sometimes restores lights
Codes mentioned: Wiring harness short/fault in main fuse box
Repairs/costs cited: Dealer replaced wiring harness but problem persisted; owner returned 4 times and dealer stated inability to duplicate issue.
Recalls/TSBs owners mention: GM called owner regarding service quality but took no action to correct electrical faults.
Curtain Air Bag Unexpected Deployment
Curtain air bags on driver and front passenger sides deployed with force without any impact or collision. Driver's hearing impacted for days and head injury sustained. Cause not diagnosed; manufacturer assigned to investigate.
When: Unspecified rate of speed while driving
Symptoms owners cite: Curtain air bags deployed forcefully without impact; Driver's hearing impacted for days after deployment; Head injury sustained; Air bags had to be maneuvered for driver to exit vehicle
Codes mentioned: Air bag sensor fault
Repairs/costs cited: Vehicle not diagnosed; owner awaiting manufacturer investigation response.
Recalls/TSBs owners mention: Manufacturer notified and assigned to investigate NHTSA campaigns 14V047000 and 14V171000 but no resolution reported.
Fire / Vehicle Total Loss Events
Two fire events documented. One started at dashboard during HVAC operation with extensive smoke; windshield melted. Another fire erupted from lower center console while ignition stuck and doors locked; vehicle completely engulfed in minutes.
When: One at 196,000 miles; timing of second event not specified
Symptoms owners cite: Smoke emitted from dashboard and vents; Fire erupted from lower center console; Doors locked during event; Ignition stuck in ON position; Vehicle total loss; complete burn to frame
Codes mentioned: Electrical system failure and internal short, Parts not available for recall repairs
Repairs/costs cited: Both vehicles total loss and destroyed; no repairs attempted.
Recalls/TSBs owners mention: Manufacturer provided no remedy for either fire event; one vehicle had pending NHTSA campaign repairs (14V047000, 14V153000, 14V171000) that could not be completed due to parts unavailability.
Gear Shift Button Sticking / Transmission Lock
Button on gear shift that must be pressed to change gears sticks and does not release properly, preventing gear selection in some cases.
When: <UNKNOWN>
Symptoms owners cite: Gear shift button sticks; Button does not release after pressing; Difficulty or inability to change gears
Repairs/costs cited: No specific repair details provided by owners.
Door Lock and Window Control Failures
Power door locks fail to operate automatically or mechanically; front passenger door locks remain stuck. Driver-side door handle breaks. Power window switches on driver's door burn and fail; windows stop operating intermittently. Safety lock on driver controls does not lock rear passenger windows.
When: Ongoing throughout ownership
Symptoms owners cite: Door locks will not unlock automatically via key fob or button; Doors lock themselves with occupants inside; Power window switches overheat and burn; Windows inoperative intermittently or permanently; Driver-side door handle broken; Safety child lock does not prevent rear window operation
Codes mentioned: Electrical power distribution fault, Relay/switch failure
Repairs/costs cited: Window switches not repaired under warranty despite being in-warranty; owner disabled and did not use them.
Recalls/TSBs owners mention: Dealer declined warranty coverage citing it as owner issue despite being in-warranty period.
Synthesized from 117 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 5 most recent
The service ecs does not go off. Theirfor the car will not go unless the roads are completely free of snow and ice. The car just sits and spins. Traction control light on constantly .can not drive car in winter months
Tl* the contact owns a 2009 Chevrolet hhr. While driving 45 MPH, the contact noticed that the air bag warning light became illuminated. The vehicle was taken to a dealer where it was not repaired. The failure mileage was 119,000.
The hhr won't start. Came out from work and the key won't turn in the ignition and the steering wheel is locked. Everything is locked up.......I can't get the car to start. *tr
Tl* the contact owns a 2009 Chevrolet hhr. On several occasions, the vehicle would not start and a burning odor was present inside the vehicle. The vehicle was taken to the dealer who was unable to diagnose the cause of the failures. No further information was available. The manufacturer was notified. The VIN was not available. The failure mileage was 26,000.
The ESC has gone out and the turn signals work, but now I have to turn them off manually. The ignition has been replaced twice. Once when it was new because the ignition would not turn off. The second time was a recall. The digital display which includes the radio, and information system turns on and off intermittently.
Had electrical trouble with your 2009 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 2009 Chevrolet HHR?
It's a meaningful issue. 117 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $850.
At what mileage does the electrical typically fail?
Across the 89 complaints that reported odometer mileage, most electrical failures cluster between 40,000 and 84,500 miles, with the median around 55,000. A quarter of owners report trouble before 40,000; a quarter make it past 84,500. 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/2009/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.