I have researched the Prius headlight problem from the bottom up. Toyota made a design flaw in the headlights. They have now supposedly fixed this problem. I went to the dealership and they put in new headlight bulbs and no problems have occurred ever since. Buy OEM headlights, nothing else will work. I know, I tried.
I second that. I tried generic bulbs (D4R) and they were no better than the one's I replaced. They shut off every few minutes and were not very bright. I then spent $95 for a pair of real (I think, you never know on ebay) OEM D4R's and no more problems. They are marked just like the originals: Philips D4R. Finally, my headlights are like new again.
Amazon has Phillips for $54 bucks..... http://www.amazon.com/dp/product/B00480J4J6?tag=priuschatcom-20 If you Google Phillips D4R price, you can find inexpensive replacements all over the place!
I bought and installed these on my '06 Prius about two months ago. They're working just great so far... http://www.amazon.com/gp/product/B002GZ70LY/
could you share with me some of the info you got on the headlights, i.e. references and such? I would like to know more...also, did the dealership install their bulbs, or did you buy your own? how long have you had the new ones? What did it cost? the dealership here wants $500 which to me seems outrageous...is there a consumer advocacy group that knows about this?? Thanks! : )
There is a Toyota settlement for the headlights, its posted on here. Toyota finally forced to pay for 2006-2009 Prius headlight repairs | PriusChat