Headlight Harness Is Melting

CarComplaints.com Notes: The 2009 is starting to have the same problems as previous model years, including the headlights blowing out due to bad connectors.

The wiring harness connections aren't a big deal to replace, as long as your dealer or mechanic doesn't charge you an arm & a leg to "diagnose" the problem.

7.1

pretty bad
Typical Repair Cost:
No data
Average Mileage:
70,650 miles
Total Complaints:
7 complaints

Most Common Solutions:

  1. not sure (5 reports)
  2. cleaned socket and reconnected (2 reports)
2009 Pontiac G6 lights problems

lights problem

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2009 Pontiac G6 Owner Comments

problem #7

May 122016

G6 GS 3.5L V6

  • Automatic transmission
  • 81,325 miles

A D V E R T I S E M E N T S

click to see larger images

headlight harness is melting

First it was the driver's side headlight connector. Partially melted. Now the passenger side has melted & unconnected the wiring!! Not sure how much this will cost. There needs to be a RECALL issued for this before someone gets hurt or worse! I mean, both headlight connectors melting? I managed to keep the driver side working, the passenger side connector is shot! What poor workmanship. Unacceptable!!

- Mark P., Bedford, US

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problem #6

Jul 222016

G6 LS 2.4L

  • Automatic transmission
  • 43,000 miles

Like other Pontiac G6 owners I am having issues with the headlight plug melting...... so I take it GM will wait until there are a bunch of fires and a death or 2 before issuing the recall?

- Floyd P., modesto, American Samoa

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problem #5

Jul 152016

G6 4 DR V6

  • Automatic transmission
  • 109,000 miles

Drivers side low beam headlamp was not working. Bought a bulb, an then noticed the light was back on. It went out again three weeks later. Replaced the bulb, but found it still would not work and noticed the connector to the bulb had partially melted and two black wires were not well connected from the factory. Tried securing the wires and head sparking noises as the light went on for a brief second. Wiring is too light to handle which has caused a fire risk. I have three GM vehicles, but am rethinking our next purchase since this is an obvious safety issue which warrants a recall by General Motors.

I see there is a Technical Service Bulletin: TSB Reference:

#SB-10-08-42-001A, see link: http://www.pontiacproblems.com/tsbs/G6/2009/ which tells the dealer to inspect bulb and connector, but do not replace the entire assembly. Will take it in and see what they suggest.

- M S., Oconomowoc, WI, US

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problem #4

Oct 022015

G6 2.4L V4

  • Automatic transmission
  • 60,000 miles

A D V E R T I S E M E N T S

This is the third time I have fixed this problem. Driver's side headlight (low beam) goes out. I can see that the wiring harness connector is melted. I see this complaint a lot on the Internet. Apparently, the connector is heating up and melting. I have cleaned it and plugged it back in and good to go until next time. This last occurrence caused the other headlight to malfunction ( apparently bulb blew out). This is my wife's car and she is not happy, which means I am not happy. I notice that other GM cars are recalled for this but not Pontiac.

- lous, Jefferson Hills, PA, US

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problem #3

Feb 262015

G6 4 cyl

  • Automatic transmission
  • 98,052 miles

I have had to remove the headlight assembly numerous (over 5) times to push the connection together on the driver's side low beam light assembly. After reading the posts here, I have further looked at the harness and have noticed the low beam assembly is in fact melted causing a short to the low beam light. The only solution to this problem is to either replace the entire headlight assembly ($$$) or to to rob one off and similar vehicle at the junk yard. This is obviously and manufactures problem and should be addressed by GM. I have also spoken with other Pontiac G6 owners who are also experiencing this same issue.

- Jason W., Clarksville, TN, US

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problem #2

Jan 052015

G6 V6

  • Automatic transmission
  • 37,232 miles

Driver's side headlight went out. Replaced bulb and that went out two days later. Just learning now from reading complaints that it's not the bulb. Need to replace harness but I have no garage and it's 10 below zero here. Pontiac apparently knows about this but is ignoring. Just bought the car in December 2014, will be getting rid of it by summer, if Pontiac doesn't issue the recall.

- Ken E., Garden City, MI, US

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problem #1

Oct 152014

G6 2.4L

  • Automatic transmission
  • 65,600 miles

Headlight On driver side stopped working. I being a car guy, looked it up on YouTube. As I took the bulb out of the harness I saw that the harness has started to melt. I checked the Contact and it was black with Carbon. I Used a small File and cleaned the contact. I bench tested the bulb, it was fine. I was careful not to let My Body oils tough the bulb. I re-installed the headlight assembly and it worked. Fast forward two months and the light quit working. I have not taken it apart, Yet! I now believe that the harness will need to be replaced, the cost $66.00.. I belong to a G6 Forum on Facebook, this is a common Problem. This is a factory defect that should be on a recall. My car has always been Garaged. This is a case of the wires not heavy enough to handle the amps. ......

Update from Feb 12, 2015: Cleaned the Contacts and it worked for a Couple of Months...Believe there should be a Recall...they get to Hot and Melt!1

- Robert E., Placentia, CA, US

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