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2003 Pontiac Sunfire

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2003 Pontiac Sunfire do not stand out strongly from the model-year median of 77.

About this comparison →

When problems were reported

Mileage at the reported incident

52 reports with mileage · 20 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Exterior Lighting. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

4 crash reports1 fire reports3 injury reports

Electrical System complaints

23 reports
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Mileage unknown · Apr 10, 2008
Electrical System

DRIVING TO THE STORE ONE NIGHT I REALIZED HALFWAY THERE, MY DASH LIGHT BEHIND THE FUEL GAGE WAS ALMOST OUT AND THEN REALIZED EVERYTHING ILLUMINATED BY MY HEADLIGHTS LOOKED VERY DIM, LIKE THEY WEREN'T ON, JUST MY FOG LIGHTS. I PULLED OVER TO FIND THAT IT WAS JUST MY FOG LIGHTS, I HAD NO LOW BEAMS YET THE SWITCH SHOWED MY LIGHTS…

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DRIVING TO THE STORE ONE NIGHT I REALIZED HALFWAY THERE, MY DASH LIGHT BEHIND THE FUEL GAGE WAS ALMOST OUT AND THEN REALIZED EVERYTHING ILLUMINATED BY MY HEADLIGHTS LOOKED VERY DIM, LIKE THEY WEREN'T ON, JUST MY FOG LIGHTS. I PULLED OVER TO FIND THAT IT WAS JUST MY FOG LIGHTS, I HAD NO LOW BEAMS YET THE SWITCH SHOWED MY LIGHTS TO BE ON. THANKFULLY NO POLICE WERE AROUND, I'VE BEEN TOLD DRIVING WITHOUT YOUR LIGHTS ON IS A RED FLAG TO THE POLICE THAT YOU MAY BE DRIVING DRUNK OR DRIVING RECKLESSLY, WHICH NEITHER WAS THE CASE. LUCKILY A FRIEND WAS DRIVING BEHIND ME AND PULLED OVER AT THE SAME TIME. WE BOTH LOOKED AT IT AND THEN HE HAD TO HELP ME GET BACK HOME, DIDN'T KNOW I HAD HIGH BEAMS STILL. I'VE TRIED EVERYTHING TO FIGURE OUT WHAT'S WRONG AND STILL WORKING ON IT 6 MONTHS LATER. I'M NOW ON A DISABILITY INCOME AND CAN'T JUST BRING IT TO THE DEALER/MECHANIC TO SEE IF THEY MAY OR MAY NOT BE ABLE TO FIX IT AND END UP WITH AN OUTRAGEOUS BILL, ESPECIALLY IF I HAVE TO KEEP GOING BACK. I WAS DOING RESEARCH TO SEE IF I MISSED A RECALL OR AN ARTICLE STATING THE PROBLEM & FIX WITH THIS ISSUE WHEN I FOUND THIS WEBSITE AND SEE THAT IT HAS AN AWFUL LOT OF THE SAME COMPLAINTS AS MINE. KIND OF A RELIEF. AFTER READING MOST OF THEM, I STILL HAVEN'T FOUND A COMMENT/COMPLAINT THAT SAYS EXACTLY WHAT THE ISSUE IS AND IF IT'S EXPENSIVE. IF I'M NOT THE ONLY PONTIAC OWNER WITH THIS ISSUE AND AT A LOSS, WHAT SHOULD I DO NEXT BESIDES THE OBVIOUS? IS THERE AN ACTUAL FIX FOR THIS PROBLEM THAT I HAVEN'T READ/FOUND YET OR WHEN THERE IS ONE, WILL I/WE BE NOTIFIED? *TR

NHTSA ODI #10224115

80,000 miles · Sep 28, 2007
Air BagsElectrical SystemExterior Lighting

I PURCHASED THE CAR IN OCTOBER 2003 AND THE CAR WAS GREAT. IN MARCH 2006 I STARTED HAVING PROBLEMS WHERE THE CAR WHEN ATTEMPTED TO START WOULD TAKE A FEW SECONDS EXTRA AND THEN START, THEN 6 MONTHS LATER I WAS DRIVING DOWN THE STREET AND THE CAR JUST CUT OFF IN THE MIDDLE OF AN INTERSECTION. THE CAR RESTARTED ABOUT 10 MINUTES LA…

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I PURCHASED THE CAR IN OCTOBER 2003 AND THE CAR WAS GREAT. IN MARCH 2006 I STARTED HAVING PROBLEMS WHERE THE CAR WHEN ATTEMPTED TO START WOULD TAKE A FEW SECONDS EXTRA AND THEN START, THEN 6 MONTHS LATER I WAS DRIVING DOWN THE STREET AND THE CAR JUST CUT OFF IN THE MIDDLE OF AN INTERSECTION. THE CAR RESTARTED ABOUT 10 MINUTES LATER. THEN IN NOVEMBER THIS STARTED HAPPENING MORE AN MORE FREQUENTLY. ONE NIGHT IN DECEMBER THE CAR CUT OFF AND WOULD NOT RESTART AT ALL. I WAS ABLE TO PULL OF THE ROAD. I WAITED AN HOUR AND STILL THE CAR WOULD NOT START. I CAME BACK THE NEXT DAY AND THE CAR WOULD NOT START. I GOT THE CAR TOWED TO A MECHANIC WHO SAID THAT HE THOUGHT IT WAS THE FUEL PUMP SO I REPLACED THAT AND THE CAR WORKED FOR 2 DAYS AND THEN THE SAME PROBLEM AGAIN. HE THEN TESTED THE CAR AND SAW THERE WAS NO POWER GOING TO THE FUEL PUMP. I HAD HIM DO A TEMPORARY FIX AND RUN A LINE FROM THE BATTERY TO THE FUEL PUMP SO THE CAR WOULD STILL START. THEN EVERYTHING ELSE SLOWLY STARTED TO FAIL. THE AIR BAG LIGHT WOULD COME ON INTERMITTENTLY AND NOW STAYS ON. ONE LOW BEAM HEADLIGHT WENT OUT AND THEN THE OTHER FOLLOWED BY MY HIGH BEAM TOTALLY. MY FRONT LEFT TURN SIGNAL WENT THEN THE REAR RIGHT FOLLOWED BY THE FRONT RIGHT. MY HORN NO LONGER WORKS. I DON'T KNOW IF MY AIRBAGS WOULD DEPLOY IF I WAS IN AN ACCIDENT. THE WINDSHIELD WIPER RECENTLY STOPPED WORKING AS WELL. *JB

NHTSA ODI #10204414

95,000 miles · Apr 26, 2007
Electrical System

FAILURE IS IN THE LEFT AND RIGHT DIM HEADLIGHTS. THE LEFT WENT OUT 1 WEEK AGO. THE SERVICE LIGHT CAME ON AND THERE WAS A CONSTANT CLICKING NOISE UNTIL THE LIGHTS WERE TURNED ON (SIMILAR SOUND WHEN TURN SIGNAL LAMPS GO OUT). THE BULB WAS REPLACED AND THE SERVICE LIGHT WENT OFF. THE LIGHT STILL DID NOT WORK AND THE CLICKING NO…

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FAILURE IS IN THE LEFT AND RIGHT DIM HEADLIGHTS. THE LEFT WENT OUT 1 WEEK AGO. THE SERVICE LIGHT CAME ON AND THERE WAS A CONSTANT CLICKING NOISE UNTIL THE LIGHTS WERE TURNED ON (SIMILAR SOUND WHEN TURN SIGNAL LAMPS GO OUT). THE BULB WAS REPLACED AND THE SERVICE LIGHT WENT OFF. THE LIGHT STILL DID NOT WORK AND THE CLICKING NOISE WAS THE SAME. THE OLD BULB DID NOT HAVE THE FILAMENT BURNT OUT. TODAY THE RIGHT BULB HAS DONE THE SAME THING. BOTH BULBS HAVE BEEN REPLACED AND STILL THE SAME RESULTS. NO HEADLIGHTS. BRIGHT HEADLIGHTS STILL WORK. LUCKILY THIS HAPPENED DURING THE DAY ELSE MY WIFE WOULD HAVE HAD A HECK OF A TIME GETTING AROUND AND AVOIDING AN ACCIDENT DUE TO LOSS OF VISIBILITY. CURRENTLY THIS CONDITION STILL EXISTS AND WE ARE SWAPPING VEHICLES TO PLAY THE DRIVE DURING DAYLIGHT GAME. FROM THE RESEARCH I HAVE FOUND THIS IS FAIRLY COMMON TO THE PONTIAC SUNFIRE. POOR ELECTRICAL WIRING HARNESS. *JB

NHTSA ODI #10189064

60,000 miles · Mar 26, 2007
Electrical System

HAVING NUMEROUS PROBLEMS WITH THE HEADLIGHTS. STARTED WITH DIM LIGHTS THEN TO NO LOW BEAMS, AND NOW ONLY ONE HIGH BEAM. BY RESEARCHING ON THE INTERNET I AM CERTAINLY NOT THE ONLY ONE WHO HAS HAD THE SAME PROBLEMS WITH VERY EXPENSIVE REPAIRS. THIS TO ME SEEMS LIKE A VERY DANGEROUS PROBLEM. MAYBE NO ONE WAS KILLED AS A RESULT ,BUT…

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HAVING NUMEROUS PROBLEMS WITH THE HEADLIGHTS. STARTED WITH DIM LIGHTS THEN TO NO LOW BEAMS, AND NOW ONLY ONE HIGH BEAM. BY RESEARCHING ON THE INTERNET I AM CERTAINLY NOT THE ONLY ONE WHO HAS HAD THE SAME PROBLEMS WITH VERY EXPENSIVE REPAIRS. THIS TO ME SEEMS LIKE A VERY DANGEROUS PROBLEM. MAYBE NO ONE WAS KILLED AS A RESULT ,BUT HOW MANY WOULD HAVE TO FOR A RECALL TO FIX THIS PROBLEM. I THINK PONTIAC NEEDS TO ADDRESS THIS ISSUE WITH A RECALL.*AK

NHTSA ODI #10186237

94,515 miles · Feb 11, 2007
Electrical System

TURNED THE CAR OFF , WENT IN THE STORE, CAME OUT AND THE CAR WAS FULL OFF BLACK SMOKE. THE WIRE HARNESS MELTED FROM THE FUSE PANEL BACK TO THE TAIL LIGHTS. DEALER SAID IT STARTED FROM A FAULTY DIODE NEAR THE FUSE PANEL, BUT WARRANTY WOULD NOT COVER IT. THANK GOD THE KIDS WEREN'T WAITING IN THE CAR. *NM

NHTSA ODI #10182273

40,000 miles · Jan 5, 2007
Electrical System

THE WIRING HARNESS ON THE VEHICLE HAS FAILED THREE TIMES SINCE 2003 CAUSING FAILURE OF THE LOW AND HIGH BEAMS ON THE HEADLIGHTS AS WELL AS THE TURN SIGNALS. MY UNDERSTANDING IS THAT THIS IS BEING CAUSED BY EARLY CORROSION. THERE IS NO WARNING OF THE IMPENDING FAILURE. THE LIGHTS IMMEDIATELY GO OUT WITH NO RECOURSE UNTIL SERVI…

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THE WIRING HARNESS ON THE VEHICLE HAS FAILED THREE TIMES SINCE 2003 CAUSING FAILURE OF THE LOW AND HIGH BEAMS ON THE HEADLIGHTS AS WELL AS THE TURN SIGNALS. MY UNDERSTANDING IS THAT THIS IS BEING CAUSED BY EARLY CORROSION. THERE IS NO WARNING OF THE IMPENDING FAILURE. THE LIGHTS IMMEDIATELY GO OUT WITH NO RECOURSE UNTIL SERVICED. THERE IS A GREAT DEAL OF DISCUSSION OF THIS COMMON PROBLEM, AND THE SERVICE DEPARTMENT HAS ADMITTED THAT THIS HAS BEEN A COMMON FAILURE. *NM

NHTSA ODI #10177874

42,000 miles · Jun 11, 2005
Electrical SystemFuel System, Gasoline

WAS DRIVING ON THE FREEWAY, TRAVELING AT 70 MPH AND ALL OF THE LIGHTS BOTH DASH AND EXTERIOR WENT OUT AND THE ENGINE STOPPED. PULLED TO THE SIDE OF THE HIGHWAY AND TRIED TO RESTART THE CAR, NO LUCK. WAITED FOR 30 MINUTES AND TRIED TO RESTART IT AND IT STARTED UP, BUT WHEN I GOT UP TO 40MPH, IT REPEATED WHAT IT DID BEFORE, PULL…

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WAS DRIVING ON THE FREEWAY, TRAVELING AT 70 MPH AND ALL OF THE LIGHTS BOTH DASH AND EXTERIOR WENT OUT AND THE ENGINE STOPPED. PULLED TO THE SIDE OF THE HIGHWAY AND TRIED TO RESTART THE CAR, NO LUCK. WAITED FOR 30 MINUTES AND TRIED TO RESTART IT AND IT STARTED UP, BUT WHEN I GOT UP TO 40MPH, IT REPEATED WHAT IT DID BEFORE, PULLED TO THE SIDE OF THE ROAD AND WAITED ANOTHER 15 MINUTES AND IT STARTED AGAIN, AND IT DID IT AGAIN. AGAIN I PULLED TO THE SIDE OF THE ROAD AND WAITED, THEN IT STARTED, AND I FINALLY GOT IT TO AN EXIT OFF OF THE HIGHWAY. IT WOULD ONLY RUN AT 25MPH, ANYTHING ABOVE THAT IT WOULD REPEAT THE SAME SYMPTOMS AS ABOVE. THE NEXT DAY AFTER LEAVING THE CAR SIT OVERNIGHT, IT STARTED JUST FINE, RAN JUST FINE, EXCEPT THE ENGINE LIGHT CAME ON. TOOK IT TO THE DEALERSHIP, AND THEY RESET THE COMPUTER, THE CODE READ THAT IT WAS RUNNING TO LEAN, THEY CHECKED, BUT COULD NOT FIND ANY PROBLEMS. THE CAR WILL NOT RUN ABOVE 70MPH, THIS HAS HAPPENED THREE TIMES SINCE THE FIRST INCIDENT. THE ONLY REPAIRS THAT WERE DONE, WERE THE RECALLS ALREADY ON FILE FOR THIS VEHICLE.

NHTSA ODI #10124992

6,178 miles · Feb 20, 2005
Electrical System

BOUGHT A 2003 PONTIAC SUNFIRE IN OCT 2003. FROM FEB OF 2004 TO FEB 2005 IT HAS BEEN IN THE SERVICE DEPT OF FRANKLIN MOTOR CO IN JASPER AL A TOTAL OF FIVE TIMES FOR THE SAME PROBLEM. THE CAR DIES IN THE MIDDLE OF THE HWY. FOR NO REASON. ALMOST GOT REAR ENDED AT ONE POINT, WAS TURNING ACROSS TRAFFIC ON A FOUR LANE HWY AND IT DIE…

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BOUGHT A 2003 PONTIAC SUNFIRE IN OCT 2003. FROM FEB OF 2004 TO FEB 2005 IT HAS BEEN IN THE SERVICE DEPT OF FRANKLIN MOTOR CO IN JASPER AL A TOTAL OF FIVE TIMES FOR THE SAME PROBLEM. THE CAR DIES IN THE MIDDLE OF THE HWY. FOR NO REASON. ALMOST GOT REAR ENDED AT ONE POINT, WAS TURNING ACROSS TRAFFIC ON A FOUR LANE HWY AND IT DIES ACROSS 2 LANES. CAN NOT MAKE THE CAR MIMIC THE PROBLEM AT ANY TIME BUT DEALERSHIP WILL NOT TAKE RESPONSIBILITY BECAUSE IT HAS NOT DONE IT WITH THEM WHILE BEING DRIVEN BY THEM. HAVE GONE THRU ARBITRATION WHICH WAS A JOKE, WAS TOLD BECAUSE OUR COMPLAINT LETTER REACHED GM COMPANY IN NOV OF 2004 THAT OUR YEAR ACCORDING TO THE LEMON LAW WAS UP. IT DIDN'T MATTER THAT WE HAD TRIED TO GET THEM TO DO SOMETHING ABOUT IT FOR THE LAST YEAR.LAWYER FOR GM COMPANY SAID THE CAR WAS NOT A HAZARD BECAUSE THERE HAD NOT BEEN AN ACCIDENT. THEY HAVE REPLACED RESONATOR AND PIPE ASSEMBLY, COMPRESSOR ASSEMBLY, & MODULE, PCM/VCM ALL ON 4/5/04.UPPED IDLE FROM 725RPM TO 925-950 RPM ON 5/28/04. REPLACE VALVE, IDLE AIR CONTROL ON 3/23/2004*JB

NHTSA ODI #10111829

Mileage unknown · Dec 1, 2004
Air BagsElectrical SystemEngine And Engine Cooling

NUMEROUS OF FAILURES;AIR BAG LIGHT CAME ON AND STAYED ON, CLUTCH STICKS TO FLOOR, CAR DOESN'T WANT TO START. *BF THE TURN SIGNALS AND LIGHTS HAD GONE OUT, IT WOULD TAKE A COUPLE OF ATTEMPTS TO START THE VEHICLE, THERE WERE TIMES WHERE THE VEHICLE WOULD START ON IT'S OWN WITHOUT THE TURN OF THE KEY, THE VEHICLE USED AN EXTREM…

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NUMEROUS OF FAILURES;AIR BAG LIGHT CAME ON AND STAYED ON, CLUTCH STICKS TO FLOOR, CAR DOESN'T WANT TO START. *BF THE TURN SIGNALS AND LIGHTS HAD GONE OUT, IT WOULD TAKE A COUPLE OF ATTEMPTS TO START THE VEHICLE, THERE WERE TIMES WHERE THE VEHICLE WOULD START ON IT'S OWN WITHOUT THE TURN OF THE KEY, THE VEHICLE USED AN EXTREME AMOUNT OF GAS, THE DASH WOULD RATTLE, THE ENGINE WOULD GROWL, THE DASH MADE A SOUND LIKE THE SPEAKER WAS BLOWN, THERE WAS A BURNING SMELL IN THE STEREO AND THERE WAS A THUMPING NOISE WHEN TURNING THE VEHICLE. (2003 PONTIAC SUNFIRE) *SC

NHTSA ODI #10109784

Mileage unknown · Jun 4, 2004
Electrical System

WHILE DRIVING 55 MPH ALL LIGHTS FROM THE VEHICLE TURNED OFF. THE CONSUMER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND PULLED OVER. THE CONSUMER TURNED OFF THE VEHICLE AND WAS UNABLE TO START IT UP AGAIN. VEHICLE WAS TAKEN TO THE DEALER THE NEXT DAY FOR INSPECTION AND THE MECHANIC COULD NOT DUPLICATE THE PROBLEM. *AK…

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WHILE DRIVING 55 MPH ALL LIGHTS FROM THE VEHICLE TURNED OFF. THE CONSUMER WAS ABLE TO MAINTAIN CONTROL OF THE VEHICLE AND PULLED OVER. THE CONSUMER TURNED OFF THE VEHICLE AND WAS UNABLE TO START IT UP AGAIN. VEHICLE WAS TAKEN TO THE DEALER THE NEXT DAY FOR INSPECTION AND THE MECHANIC COULD NOT DUPLICATE THE PROBLEM. *AK THE PROBLEM RECURRED. *SC *JB

NHTSA ODI #10071725

Official recalls

1

04V524000 · Exterior Lighting:turn Signal

Nov 1, 2004

ON CERTAIN PASSENGER VEHICLES, THE REAR LAMPS THAT PROVIDE STOP AND TURN SIGNALS AND TAIL LAMP FUNCTIONS STOP WORKING BECAUSE OF INADEQUATE CONTACT BETWEEN THE BULB AND SOCKET. IN ADDITION, IF ONE BULBS WERE TO BECOME INOPERATIVE WHILE THE VEHICLE WAS OPERATING IN CRUISE CONTROL, THE CRUISE CONTROL WOULD DISENGAGE WHEN THE REMAINING BULB WAS ACTIVATED. IF BOTH LAMPS WERE TO BECOME INOPERATIVE, THE CRUISE CONTROL WOULD NOT ENGAGE.

Consequence & remedy

Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY GREASE OR REPLACE THEM IF NECESSARY. THE RECALL BEGAN ON JANUARY 18, 2005. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR PONTIAC AT 1-800-620-7668.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA04028 · Turn Signal Malfunction

Opened Sep 14, 2004 · Closed Nov 22, 2004

Status: closed (inferred from source dates) · Exterior Lighting:turn Signal

ON MAY 14, 2004 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-043) BASED ON CONSUMER COMPLAINTS ALLEGING THAT THE BRAKE/TAIL TURN SIGNAL LAMPS WOULD NOT OPERATE PROPERLY WHEN EITHER THE TAIL LIGHTS WERE TURNED ON, THE BRAKE PEDAL WAS DEPRESSED, OR WHEN THE TURN SIGNAL SWITCH WAS ACTIVATED.ON SEPTEMBER 14, 2004 ODI UPGRADED PE 04-043 TO AN ENGINEERING ANALYSIS (EA04-028).GM STATES THAT SOME BRAKE/TAIL/TURN SIGNAL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO EXCESSIVE HEAT BUILDUP WITHIN THE BULB SOCKETS.THE CAUSE OF THE EXCESSIVE HEAT BUILD UP WAS DETERMINED TO BE A LACK OF THERMAL GREASE PLACED IN BETWEEN THE BULB AND THE SOCKET. BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V524) COVERING ALL MY 2003 VEHICLES.GM DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY THERMAL GREASE TO THEM OR REPLACE THEM WITH NEW ASSEMBLIES WITH THERMAL GREASE ALREADY ATTACHED.MODEL YEAR 2004 AND NEWER VEHICLES HAVE THE THERMAL GREASE INSTALLED FROM THE FACTORY. THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

PE04043 · Turn Signal Malfunction

Opened May 14, 2004 · Closed Sep 14, 2004

Status: closed (inferred from source dates) · Exterior Lighting:turn Signal

COMPLAINANTS ALLEGE THAT THE REAR TURN SIGNALS FAIL TO ILLUMINATE AND DO NOT PROVIDE A SIGNAL TO DRIVERS IN FOLLOWING VEHICLES.ODI HAS RECEIVED ONE REPORT OF A CRASH WHERE THE COMPLAINANT BRAKED AND ATTEMPTED TO MAKE A LEFT TURN AND THE FOLLOWING VEHICLE IMPACTED THE COMPLAINANT'S VEHICLE IN THE DRIVER-SIDE DOOR.IN MAY 2002, GM'S SUPPLIER MADE CHANGES TO THE BULB SOCKET THAT INCLUDED STOPPING THE USE OF THERMAL-MASTIC GREASE IN THE BULB SOCKET.GM REPORTS THAT THE GREASE REDUCES ARCING AT THE CONTACTS AND DISSIPATES HEAT THUS PREVENTING MELTING OF THE SOCKET MATERIAL OR BURNING OF THE CONTACTS.MOST OF THE SUBJECT VEHICLES WERE PRODUCED WITHOUT GREASE APPLIED TO THE BULB SOCKET.IN JUNE 2003, GM DIRECTED THE SUPPLIER TO RESUME THE USE OF GREASE IN THE SOCKET.GM ISSUED TECHNICAL SERVICE BULLETIN (TSB) 04-08-42-004A ON JULY 15, 2004 ADVISING TECHNICIANS TO MAKE SURE THAT ADEQUATE AMOUNTS OF GREASE WERE ADDED TO THE BULB SOCKETS ON ALL SERVICE PARTS.ODI WILL UPGRADE THIS INVESTIGATION TO EA 04-028 TO FURTHER EXAMINE THE ISSUE.