Denso Ballast?
06-01-12, 05:32 AM
#1
Denso Ballast?
Hey all,
I have an 06 IS250 with factory HID and auto level and such.....
had my drivers headlight go out again. replaced bulbs twice already (2 separate occasions)and they were both working. currently have my drivers side out again out so I switched bulbs from drivers side to pass side. and the problem stayed with the drivers side.....light turns on for about 3 minutes then flickers and goes out. So I assume its the ballast as the connector cap insides don't look burnt or anything.
Did some research on how to replace it and I just don't feel comfortable baking the headlight or using a "heat gun". especially with the $1200 price tag for replacing 1 side headlamp. Just doesn't make sense to have a $2400 bill every 7/8 years. So I searched and found 2 ideas that I'd like some input on. Bought two OEM Denso D4S new online.
1. Since the caps look good I was thinking of cutting the steel-ish braid and the two wires that go to the cap and soldering them to the new ballast. that way I don't need to take anything apart. I don't see a problem with this as its just two wires and the steel-ish braid. and wires are wires. anyone else find an issue with it?
2. This is a dumb question due to the word danger printed on the ballast. but why can I not open the ballast? I know they sell re-furbished ballasts so I'm wondering why I cant crack it open to remove the wires from inside the ballast housing without cutting.
Does anyone else have any ideas. I've had too many headlights with water and my family mechanic wont warranty his work if he attempts to bake them. no to mention he charges $125 an hour.
Cheers,
I have an 06 IS250 with factory HID and auto level and such.....
had my drivers headlight go out again. replaced bulbs twice already (2 separate occasions)and they were both working. currently have my drivers side out again out so I switched bulbs from drivers side to pass side. and the problem stayed with the drivers side.....light turns on for about 3 minutes then flickers and goes out. So I assume its the ballast as the connector cap insides don't look burnt or anything.
Did some research on how to replace it and I just don't feel comfortable baking the headlight or using a "heat gun". especially with the $1200 price tag for replacing 1 side headlamp. Just doesn't make sense to have a $2400 bill every 7/8 years. So I searched and found 2 ideas that I'd like some input on. Bought two OEM Denso D4S new online.
1. Since the caps look good I was thinking of cutting the steel-ish braid and the two wires that go to the cap and soldering them to the new ballast. that way I don't need to take anything apart. I don't see a problem with this as its just two wires and the steel-ish braid. and wires are wires. anyone else find an issue with it?
2. This is a dumb question due to the word danger printed on the ballast. but why can I not open the ballast? I know they sell re-furbished ballasts so I'm wondering why I cant crack it open to remove the wires from inside the ballast housing without cutting.
Does anyone else have any ideas. I've had too many headlights with water and my family mechanic wont warranty his work if he attempts to bake them. no to mention he charges $125 an hour.
Cheers,
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09-05-12, 06:48 PM
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I saw the video and looks great thx, except I don't understand how I can pull the ballast out if its still connected to the headlight. If my ballast is burnt out I would need to remove it from the inside of headlight yah?
09-05-12, 07:04 PM
#10
You must remove your headlight all together, once out you must remove 4 screws holding down the ballast. You will pull on the cord however because the socket that plugs into your bulb is too big it will hit the AFS motor when you try to pull it through. This video shows you how to dissamble the socket allowing you to pull the cord through.
09-05-12, 08:27 PM
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Im having the exact problem on my 07 model. Where did u order the ballast from and how much if u dont mind me asking. Dealer wants 2200 for 2 new whole headlamps with ballast
09-05-12, 10:13 PM
#12
I definitely forgot to post on this after I did the install 
. The link posted on here for socket disassembly is great but if you look at any other videos or pictures of a Baking DIY you will see that inside there is a screwed in clip that secures the wires to the back of the headlamp housing. While taking off the ballast cap is a great idea, I personally didn’t feel like it would be safe for me to thread wires in a housing that has AFS and a decent amount of moving parts due to the AFS. So I did something that actually worked for me considering my background. The ballast has a red and white wire in the steel braid that go to the cap. I did the following and it has worked for me without issues for 3 months including many many many car washes.
1. Remove bumper and disconnect the headlamp from the wire connector, thus completely removing the entire headlamp housing from the vehicle.
2. With the headlamp housing removed, unscrewed all of the wire holders on the underside of the housing.
3. Unscrewed the 4 screws of the ballast.
4. Cut the braid and red/white wires close to the old ballast.
5. Cut the braid with meat on it from the new ballast and connect them to the wires that I cut above.
6. Make the connections, taped, and head shrunk wires.
7. Removed old ballast caps, via that posted video, and attached the new caps from the new ballast - you need to remove the metal pins from the old wires and attach them to the new wires and reassemble the cap housing....my pins were burnt out and partially missing.
8. Essentially saved myself from baking the housing and the hassle.
lues350,
To answer where I bought them.....I buy all my lighting needs from theRetroFitSource.com and have only good things to say about them. You have to call to buy the ballast because they are a special order item that they have to order from another dealer. Paid $200 for the pair with free shipping for them and they were at my door within a week. When you call you need to give them basic car information and tell them you want NEW Denso D4S OEM Ballasts. They said they have used ones for about $120 I think but I wanted new. Like I said no issues as of now including my installation.
Let me know if you need any more info.
. The link posted on here for socket disassembly is great but if you look at any other videos or pictures of a Baking DIY you will see that inside there is a screwed in clip that secures the wires to the back of the headlamp housing. While taking off the ballast cap is a great idea, I personally didn’t feel like it would be safe for me to thread wires in a housing that has AFS and a decent amount of moving parts due to the AFS. So I did something that actually worked for me considering my background. The ballast has a red and white wire in the steel braid that go to the cap. I did the following and it has worked for me without issues for 3 months including many many many car washes.1. Remove bumper and disconnect the headlamp from the wire connector, thus completely removing the entire headlamp housing from the vehicle.
2. With the headlamp housing removed, unscrewed all of the wire holders on the underside of the housing.
3. Unscrewed the 4 screws of the ballast.
4. Cut the braid and red/white wires close to the old ballast.
5. Cut the braid with meat on it from the new ballast and connect them to the wires that I cut above.
6. Make the connections, taped, and head shrunk wires.
7. Removed old ballast caps, via that posted video, and attached the new caps from the new ballast - you need to remove the metal pins from the old wires and attach them to the new wires and reassemble the cap housing....my pins were burnt out and partially missing.
8. Essentially saved myself from baking the housing and the hassle.
lues350,
To answer where I bought them.....I buy all my lighting needs from theRetroFitSource.com and have only good things to say about them. You have to call to buy the ballast because they are a special order item that they have to order from another dealer. Paid $200 for the pair with free shipping for them and they were at my door within a week. When you call you need to give them basic car information and tell them you want NEW Denso D4S OEM Ballasts. They said they have used ones for about $120 I think but I wanted new. Like I said no issues as of now including my installation.
Let me know if you need any more info.
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