Headlight Bulbs Dropping like Flies!!!

[cep]

Have you checked the voltage going to the headlamps? High voltage will kill bulbs.

[Audiomechanic]

I haven't but I will the next time one blows (which probably won't be long).

What would cause a high voltage situation?

[cep]

Poor voltage regulation, i.e., the alternator putting out too high of a voltage.

[Audiomechanic]

Ah, makes sense. The voltage regulator on these alternators is internal correct?

Well, hopefully the daytime running lamp mod will help a bunch since daytime driving makes up about 90% for us.

[Audiomechanic]

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAHHHHHHHHHHHHHHHHHHHHHHH!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

ANOTHER ONE WENT BAD!!!!!!! This makes number 6 or 7 in the 6 months we've owned the car.

I'll be checking the voltage this time.

[scholzee]

There is a problem with your wiring harness inside the head light. I will find the link which describes it there is a TSB from dealers.

[scholzee]

This will fix it !!!beetleheadlight.pdf

[Audiomechanic]

So...it needs new headlight harnesses?

[scholzee]

My passenger light was doing that and the wire harness, which is the one inside the headlight and includes the connector part of the headlight, fixed my problem. I actually have a brand new in the box vw one. I can mail it to you and try it for awhile, if your happy it fixed it you can then send me $35 plus what ever the shipping is, I believe I paid $65 at the dealer for it.

[Audiomechanic]

Originally Posted by scholzee

My passenger light was doing that and the wire harness, which is the one inside the headlight and includes the connector part of the headlight, fixed my problem. I actually have a brand new in the box vw one. I can mail it to you and try it for awhile, if your happy it fixed it you can then send me $35 plus what ever the shipping is, I believe I paid $65 at the dealer for it.

65 bucks?!? For some wires?!? Shewt, I'll cut/splice this thing. I did notice that the jacket around the wire that connects to the bulb itself it cracked and fallin apart but I never though anything of it since that wire is not near any others or any metal to ground it.

I'm gonna cut/splice it. I have some of those connectors that the bulb has from my speaker building. The connector will be delicate but doesn't look too bad. It'll be a frankenharness.

Couldn't make it any worse!

I'll keep y'all posted.

[Audiomechanic]

Ok, so I gutted one of the headlight assemblies (the one that was burnt out) removed the wire harness and rewired this punk. 65 bucks for 4 wires is RIDICULOUS! Hopefully, my electronics degree and soldering skills paid off.

Here's the before shots. As you can see, the jackets on all the wires are basically toast:




And here's the after shots:




So far so good. Both lights work and I installed ANOTHER new bulb in the headlight. We'll see how long this lasts.

If this works, I'll do a writeup when I do the other side. I will say, if you do not have fairly extensive wiring experience or don't have a LOT of patience working with small delicate things, this mod is not for you.

So far, my cost is $0 because I had the wire, heat shrink and connectors on hand. but if someone were to go buy this stuff, about 10 bucks for both sides would be reasonable.

[scholzee]

Audiomechanic Nice work! Did not know your skill level thats why I offered the connector. I actually bought 2 new headlights for mine and the said they did not come with connectors but they did so thats why I have extras. Did you ohm out and verify the bulbs were bad ? or was it obviously blown and burnt? If you still have a problem after your fix I would say its because you change the wire colors LOL.

[Audiomechanic]

Originally Posted by scholzee

Audiomechanic Nice work! Did not know your skill level thats why I offered the connector. I actually bought 2 new headlights for mine and the said they did not come with connectors but they did so thats why I have extras. Did you ohm out and verify the bulbs were bad ? or was it obviously blown and burnt? If you still have a problem after your fix I would say its because you change the wire colors LOL.

Thanks! And I really do appreciate your offer. I apologize for not stating that earlier.

The bulbs were visibly burnt.

And as far as the wire color, the ground wire is now black, and no longer brown. AS IT SHOULD BE!