HID Headlight Failure - Your Solution

2004 Prius

1. PROBABLY about 70K miles
2. Passenger side HID has the "wink out" issue described. No specific timing, relights when the switch is turned off then on (repeat as necessary). I HAVE used them as DRLs for a fair number of those miles so I might have worn them out.
3. Dealer? Heck no, I came straight to PriusChat!
4. Ordered new bulbs (4300K 35W D2R) from a dealer on eBay. See my post: http://priuschat.com/forums/care-maintenance-troubleshooting/50976-hid-headlight-bulb-replacement-ouch.html#post672622
5. Sold as a PAIR - $60, plus $10 shipping. No sense replacing only 1, the other will fail soon enough.
6. Hell no! *
7. Probably 10 to 15 minutes each, after the first time when I needed to go slowly to see how it all fit together
8. Put them in yesterday, no failures yet, but no opportunity to fail either, I haven't driven it anywhere. I'll know Monday night when I return from my weekly trip to MA. If I make it all the way home without a 'wink out', I 'll know it was the bulb and not something else.

* You can get the bulbs out by removing the leftmost (looking at the engine from the bumper) pop-up clip that holds the long black plastic piece across the front of the engine compartment and the pop-up clip underneath it that holds the air channel near the front of the windshield washer fluid reservoir and the fuse box cover on the driver's side. I've posted pictures in my album.
When I replaced the bulbs I found that I didn't have to undo the white electrical clip on the back of the black 'half dome' cover on the back of the headlight assembly. There is enough wire to rotate the cover with the clip on. When I did the 'check out the bulbs' disassembly, I had removed the entire front plastic piece and disconnected the white power connectors.

NOTE: you rotate the 'half dome' clockwise while standing in FRONT of the car. It might take a fair amount of pressure the first time. And when you have rotated it to the next stop, you might have to work it off. The O rings seat pretty well.

 

I would also say look and read this thread if you have not alread:

http://priuschat.com/forums/care-maintenance-troubleshooting/34584-headlight-problem.html

Lots of information on this problem in there.

Phil

 

Update on my new D2R HID bulbs installed 25 July.
Did the normal Monday trip yesterday. Headlights on from about 8:45 PM to 10 PM. NO wink out. So far so good, the old passenger side bulb winked out last week at least 8 times in two 'episodes' on the same route.

So, how many hours do I have to drive without a problem before I stop wondering if the new bulbs REALLY fixed it, or I just got lucky on a few trips

 

When (mileage) did your HID fail? - They didn't. 30,000 miles on the car so far.

Intermittant or did it just shut off? N/A

Did dealer replace it? If so, dealer name, city, state please. Nope.

Did you replace the entire headlamp assembly (including brain), just headlamp assembly, or just the HID bulb? Just the two D4R bulbs.

How much did it cost? (each or pair?) $100 aftermarket.

Did you have to remove your bumper? Nope.

How long did it take to replace? About an hour for both.

How long ago did you replace it? Any failures? About 2000 miles / 2 months ago

Anything else? Yeah. I bought online somewhere for about $100 a set of the D4R bulbs for my '07. Put them in, removing and setting the factory lights aside as spares.

The reason that I did this is I wanted to have a known good spare set of bulbs so that if one goes out, I'm not rushed into paying FAR too much for a replacement bulb at the dealer. I don't know of anyone from whom you can buy a D4R bulb both quickly and inexpensively.

 

I have two prius's a 2006 and 2008. At 34000 the left HID started quiting. The dealer replaced the bulb and itfixed it. I now have 48000 on my 2006 and the right quite. With the best extended warrenty they have it's not covered and they want $380 to replace. The service tech was good and told me that the bulbs don't have filiments and have a protection curcuit that will shut them down if there is a problem. Thats why they'll come back on by turning the lights on and off. Eventually they will go out though. I see all these other post the dealers are changing thoughs of dollars worth of part, well they are ripping their customers off. This dealer in Lexington Park Maryland was very honest with me but guess what. I'm changing the bulb myself with a $100 dollar one.

Does anyone know of a way to convert to a cheaper bulb???

 

I think I am on bulb number 6 or so.
The last one was replaced at 105,000 as a "Courtesy" to me.
Huhhhhh? You haven't fixed the problem - YET!
I am at the dealer now, and waiting for the FTR to arrive.
This should be an interesting conversation..
I sell automotive test equipment. It will be interesting to hear how this turns out. Oh, I have a spare HID in the glovebox in case this doesn't go anywhere.

 

Go get em!

 

Thanks for the tips - I was getting very frustrated trying to figure out how to remove the white electrical connector, but as you posted, it's not necessary. Also the tip about rotating the cover clockwise from the front of the car was a big help. I replaced the bulbs with about 30 minutes worth of effort using replacements from Ebay (probably the same guy "Stan" that others use.) For those doing this yourself, the space is very tight, but with a lot of effort the dome covers do come off. Once they start to move, keep going until you feel the stop. Use a marker and draw a line on the cover and housing so you know where to place it when finished.

Once done, smile at the $900 you just saved by buying the bulbs and doing the work yourself!

 

I'm on bulbs 5 and 6 also, four having failed so far over about 76,000 miles.

Here's a funny trick you can do for the mechanic at the dealer: if the bulb is out (leave the lights on when you get there so it's dark for him to see), you can do a "Fonzie" on it-- just give the headlight a sharp slap with a hand and it goes on! Does this for me, at least. Same as cycling it off and then on again.

My service tech was amused, at least.

 

Here's my story:
When (mileage) did your HID fail? 33,000

Intermittant or did it just shut off? Right headlight - intermittant

Did dealer replace it? If so, dealer name, city, state please. Yes. Under warrantee. Gladstone Toyota, Gladstone OR

Did you replace the entire headlamp assembly (including brain), just headlamp assembly, or just the HID bulb? Bulb

How much did it cost? (each or pair?) Under warranty but they said it would have cost $110.00

Did you have to remove your bumper? Don't now

How long did it take to replace? 1.5 hours

How long ago did you replace it? Any failures? 1 month

Anything else?[/quote] They wouldn't replace the left bulb and within a week I was having the same problem with that. Had that replaced also.
They said this was a known problem. When I asked why we weren't notifyed (3k more and my warranty was gone) they said it wasn't a recall. Frustrating if they know this and then charge $110.00 of a headlight bulb.

 

We used to own a 2001 Beetle. I believe that it was less than a year when the first halogen headlight bulb failed.

Volkswagon charged me $70 to change it. It was the passenger's side bulb. They said that they charged a little less because it was not the driver's side, which would have been $80, supposedly being "harder" to get at.

I later found out the "trick" for changing the headlight bulbs. Turns out the entire headlight unit "slides out" on a track. If you know where the track lever is located, it takes less than 10 minutes to change the bulb. Probably only 5 minutes when you've done it a few times. And it's really no harder for the driver's side.

Although the headlight bulb on tha VW Beetle failed when the car was well within warranty, they never offered to cover the replacement, but charged me anyway. So Volkwagon was charging owners approximately $80 for a 5 minute job with a part that I later bought in parts stores for way less than $10 (once I learned how to change them myself).

Morals of this story:
1.) Headlight bulbs go bad; just like tires, they don't last forever. Some only last a year or less depending on the make of the car and the type and installation of the bulb.
2.) Some manufacturers and dealers try to overcharge for the replacement of these. But once you know how to do it yourself, you can save a lot of money.

The usual Prius HID headlight failure mode is actually fairly benign, as you only need to turn them off for a few seconds, and then restart them for the defective bulb to come back on (in other words, the failure is intermittent). When this starts to happen, it's a warning to replace the bulb. IMO, this is better than the bulb failing completely.

Just like tires, headlight bulbs are not meant to last forever. Or for that matter, not even for 50,000 miles. When we drive our cars, and we notice that we are beginning to have less traction, or we are starting to hydroplane in conditions where we used to not have a problem, we know it's time to replace the tires. Likewise, when the Prius HID's start to "blink off", we should say "guess it's time to replace the bulb".

 

My story is similar - intermittent right headlight on my 2005 Prius. Dealer says I need a new bulb, the filament is broken and making connection sometimes. $350.00. I did not have it replaced. Now the left headlight is doing same thing and it's a safety issue. I called another dealer who said he'd have to look at it but the filament story didn't sound right to him.

I looked in the owners manual to see how to replace the bulb myself and in a yellow caution box is states not to replace a headlight, to contact the dealer.

Gathering information. Thanks to all who have posted regarding this issue -

 

Please refer to this pic of one of my small side-marker bulbs that
had gone intermittent. The problem is obvious.
.
Once a filament gets weak, due to loss of the metal it's made of
[where do you think that darkening of the inside of the envelope
comes from?], it's quite common to get into that intermittent
state. Basically, the filament finally breaks, but with such
a tiny gap that a little vibration can wiggle the two ends to
just touch each other again. At that point, they can self-weld
back together, then as the thing lights and thermal expansion
helps push the ends toward each other, the lamp can stay lit
for the duration of that on-time even over bumpy roads. On the
next cycle after cooldown, same game except that now it's lost
even more metal.
.
So bottom line is if it's intermittent and even "works" after you
smack it once, it's still time to replace. Probably the same
story with any short-arc gas discharge lamp that won't reliably
strike anymore.
.
_H*

 

2006 Prius with HID intermitten faliure, both sides.
1. 168K miles
2. Intermittantly shuts off. Resets and comes back on by cycling the headlight switch. Seems to shut off sooner early in the trip, stays on longer as the trip progresses. Both sides, but not at the same time.
3. $50 off of Amazon for 2 bulbs.
4. Did not remove bumper.
5. Took the local repair shop couple hours to do just the driver's side. I did the pass. side myself after watching in horror the local repair shop trying to dissasemble and bend the driver's side front fender in order to get more room to remove the old bulb.
6. Passenger side works, driver side goes out after about 5 min. Both headlights are now way out of adjustment.

Going to Beaman Toyota in Nashville today. Car is clearly out of warranty. Service writer on the phone sounds like 4 hours at the dealer with just bulb replacement should fix the problem. I am greatly concerned what this will cost. I need working headlights that point in the right direction.

In defense of the local repair shop; the dust cover was on very tight. I was unable to budge it myself and doubting that I read the instructions clearly as I put alot of force into turning it. Once off, there is no room to really get a hand in there and feel around. On the driver's side, the fuse container is so close to the back of the light and in the way. Passenger side has a little bit more room.

I have gotten a little comfort hearing that HID headlight replacement on a BMW is about $700 per bulb because it is a bulb and ECU assembly that gets replaced. I don't know if that is true or not, but again it gave me some comfort hearing that.

 

When (mileage) did your HID fail?

About 60k I noticed the driver side flickering. I got the intermittent off problem about 75k.

Intermittant or did it just shut off?

Intermittent

Did dealer replace it? If so, dealer name, city, state please.

Didn't bother with them after reading PriusChat.

Did you replace the entire headlamp assembly (including brain), just headlamp assembly, or just the HID bulb?

Just the bulbs. Replaced both and kept the working one from the passenger side just in case.

How much did it cost? (each or pair?)

$70/pair from EBay.

Did you have to remove your bumper?

No. But I did have to remove the washer fluid bottle. I have big hands though. The biggest reason I had to pull it was that the stupid spring clip fell out and I needed to see it to put it back in.

How long did it take to replace?

About an hour.

How long ago did you replace it? Any failures?

A few days. No problems yet. Really, with the EBay option available for proven bulbs, just buy a pair and replace them. It's not that hard. If you don't want to do it, find someone who can help you with the labor. A local garage mechanic shouldn't have any trouble with it.

 

Yeah, but the "ebay option" requires that you sign up with ebay,
which has plenty of its own issues. How about some alternative
sources?
.
_H*

 

I have replaced the drivers side HID at a dealer recently


When (mileage) did your HID fail? started to fail at about 40,000. Intermittent...replaced it at 52,000
Intermittant or did it just shut off?

Did dealer replace it? If so, dealer name, city, state please. Bernardi Toyota Natick , MA

Did you replace the entire headlamp assembly (including brain), just headlamp assembly, or just the HID bulb? Just the bulb

How much did it cost? (each or pair?) $243

Did you have to remove your bumper? Don't know, I think just the Bumper Cover (14 screws)

How long did it take to replace? Was at the dealer for just over an hour

How long ago did you replace it? Any failures? About a Year ago.

Anything else?[/quote] The Passenger side headlight is starting to fail goes out intermittently. at 62,000 miles

 

I read Prius chat before I bought my 09 Prius and took a paper to the dealership stating they would pay labor for all broken HID headlights, we both signed it. So far I have no problems and no worries.