2nd Gen Non-Engine/Transmission Head Lights keep blowing

[m1ashooter]

This POS has now taken to eating headlight bulbs, this is the 4th one in 2 weeks. 1998 12V, I thought the first one maybe I touched the bulb, so I wore clean gloves, next one blew. Then I went to latex gloves, still blew it. Then I thought maybe I didn't install it right, 4th one blown.



I got the first from Autozone, blamed a faulty bulb, next 2 came from NAPA, last from the stealership.



tally is one blown on the drivers side, 3 on passenger side. Any ideas or has anybody had this happen?



at least I am learning the meaning of nickel and diming to death. #@$%!

 

[BK]

man that sux.

besides the greasy finger issue, can't think of another reason for them blowing soo quickly.

does it seem like there is any excessive moisture in there, lens assy not draining?

 

[m1ashooter]

there is some condensation I can see inside the plastic assembly, but it is the same as when I bought the truck.



I guess this time I will clean the new bulb with alcohol, it's just such a PITA to remove the battery and holding tray to get to the bulb. Thought maybe I was missing something easy.

 

[BK]

As I understand it, the lens are mean to be vented.

I'm assuming if you get some condensation on the bulb it could cause it to burn out as well.
?

Maybe try and enlarge the drain hole that is there, or make sure it's clear.

 

[dresslered]

Is the glass on the bulb breaking or just the filament burning out? The shattering glass would be a result of oil/grease on the bulb which it doesn't sound like since your are being careful during the install. Also, I have to ask, but is the filimant really broken (no continuity acrossed it) or could we have corroded contact problems? Finally I assume you are using the 9004 bulbs?

 

[m1ashooter]

9004 bulbs.



yes, the glass is shattered,



I am guessing the filaments break when the glass goes.



after this last one blew, I clicked high beams on, they worked for maybe 2 seconds then the filaments self destructed.



I am going to enlarge the drain hole, this has got me stumped.

 

[Allnew2Me]

I had this happen in an old Ford truck when the voltage regulator went out. The wipers went faster than usual and the lights were really bright. Our trucks have the voltage regulator function as part of the PCM. You might check the voltage at the battery while the truck is idling to see what it is. I believe a normal voltage without anything on (including grid heaters) should be somewhere around 13. 8-14. 2. Anything much above that might point to a voltage issue. I don't thing that would break glass but it is one easy thing to check.

 

[BK]

the condensation could do that as well as the greasy finger prints.


dresslered had a lot of good points too if there wasn't carnage happening, just the light going out.

I alway use bulb grease in the socket to protect from those such problems.

 

[BK]

in the cold weather it could be as high as 14. 7 and still be in spec.
13. 6-14. 2 if a good window for fair weather temps.

With the old relay regs went out, you could hit 18+ volts.

 

[dresslered]

yes, the glass is shattered,

I am guessing the filaments break when the glass goes.

m1ashooter,

With the glass breaking, it really sounds like some kind of contaminant on the bulb, but a mystery why all of your bulbs were dirty. Once the vacuum is lost when the glass breaks, the filament will just burn up. I was going to suggest that you clean the bulbs with alcohol, but it sounds like you are already doing it--I'll be curious to hear how these work out.



Obviously, if you have a high-voltage issue, this can also shorten the lifespan considerably. However, I would imagine that you would have other issues rather than just headlights.



One last though; I know that you said that you have a bone stock truck, but is there any chance that you have a brite box installed? This leaves both high/low filaments on during high-beam operation that creates way too much heat in my opinion.

 

[Matt42]

What was the country of origin of the bulbs? Some far eastern sourced bulbs are of poor quality, even if they are boxed under a "name" brand.

 

[JDKammin]

I had a brite box on my 94. I had it tied into the drivers side headlight harness and would frequently blow out the drivers side bulb. I took the bite box off.

 

[m1ashooter]

no brite box.



This time it has a different brand, instead of the Sylvania, GE bulb. So far so good.