DORMAN OEM ballast replacement issue
02-09-19, 08:45 AM
#1
Intermediate
Thread Starter
DORMAN OEM ballast replacement issue
Hello guys. just wanted to touch base on an issue i had recently. actually i should say still have.
recently noticed flicker on my pass headlight. i did the basics of replacing the bulb itself and still happened as intermittently as before.
so hoped on dorman site to order a ballast. prior to this I used to work at a body shop. Im used to replacing these units the only way i know how which is taking apart bulb connector, separating the metal shell, splitting the two plastic housings and separating the wires. no cutting needed. taked me about 10 minutes, typically.
so i figured this should be easy. nope
ive never had an issue with this method, again, the only way i knew/ow how to install these. while attempting to separate the plastic tab on one side (which i do warm up with a heat gun to help the plastic be a tad bit forgiving) it cracked on me. no biggie, tried the other side, crack. fack!. tried the top, crack!. faaack.
at this point i was pretty ****ed, so I decided DESTROY ALL THE THINGS!. I ended up having to take apart the back piece in pieces. turns out Dorman has started adding an adhesive to the back portion of the plastic housing. which prevents separation from the housing.
taken apart these prior never seen that with Dorman replacements. i went ahead and tried to see if i could separate the ballast, desolder the connected point and give you guys a work around if your a skilled solder user, nop. seems like they sealed it with the same gunk there as well and cant be cracked open either.
so there it is, 40 bucks down the drain. but an important lesson learned and hopefully someone sees this b4 they buy it.
im guessing my best bet is just buying a dealer unit and hoping they haven't started doing this, ad making sure its a new unit not a reman.
p.s. sorry for the lack of pictures, phone took a dookie and i already threw away the ballast.
so my issue is still happening. just wondering if anyone knows a method of installing these ballast WITHOUT taking apart? or is it the only known method?
im avoiding cutting the wires, dont wanna mess with the shielding, dont wanna hack up headlight back plastic assembly.
recently noticed flicker on my pass headlight. i did the basics of replacing the bulb itself and still happened as intermittently as before.
so hoped on dorman site to order a ballast. prior to this I used to work at a body shop. Im used to replacing these units the only way i know how which is taking apart bulb connector, separating the metal shell, splitting the two plastic housings and separating the wires. no cutting needed. taked me about 10 minutes, typically.
so i figured this should be easy. nope
ive never had an issue with this method, again, the only way i knew/ow how to install these. while attempting to separate the plastic tab on one side (which i do warm up with a heat gun to help the plastic be a tad bit forgiving) it cracked on me. no biggie, tried the other side, crack. fack!. tried the top, crack!. faaack.
at this point i was pretty ****ed, so I decided DESTROY ALL THE THINGS!. I ended up having to take apart the back piece in pieces. turns out Dorman has started adding an adhesive to the back portion of the plastic housing. which prevents separation from the housing.
taken apart these prior never seen that with Dorman replacements. i went ahead and tried to see if i could separate the ballast, desolder the connected point and give you guys a work around if your a skilled solder user, nop. seems like they sealed it with the same gunk there as well and cant be cracked open either.
so there it is, 40 bucks down the drain. but an important lesson learned and hopefully someone sees this b4 they buy it.
im guessing my best bet is just buying a dealer unit and hoping they haven't started doing this, ad making sure its a new unit not a reman.
p.s. sorry for the lack of pictures, phone took a dookie and i already threw away the ballast.
so my issue is still happening. just wondering if anyone knows a method of installing these ballast WITHOUT taking apart? or is it the only known method?
im avoiding cutting the wires, dont wanna mess with the shielding, dont wanna hack up headlight back plastic assembly.
02-09-19, 12:53 PM
#3
Intermediate
Thread Starter
edit im assuming depo styles may have more room than stock in the assembly?! mine is an 09 with i believe AFS
Last edited by Wh0pp3r; 02-09-19 at 12:56 PM.
02-09-19, 01:40 PM
#5
Intermediate
Thread Starter
02-09-19, 02:14 PM
#7
Intermediate
Thread Starter
thats the method ive used for years.
which again im reiterating ive only ran into this issue with a Dorman unit. AFAIK new DENSO units shouldn't be sealed so that will be my next approach.
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opeldean (12-22-22)
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02-09-19, 02:55 PM
#8
YEAH. THATS THE METHOD, that no longer works with DORMAN because they epoxy the black plastic assembly of the bulb connector together. also they epoxy seal the ballast unit itself.
thats the method ive used for years.
which again im reiterating ive only ran into this issue with a Dorman unit. AFAIK new DENSO units shouldn't be sealed so that will be my next approach.
thats the method ive used for years.
which again im reiterating ive only ran into this issue with a Dorman unit. AFAIK new DENSO units shouldn't be sealed so that will be my next approach.
The following users liked this post:
opeldean (12-22-22)
02-12-19, 11:27 AM
#9
Intermediate
Thread Starter
Apperantly theres a method of removing the AFS motor and making just enough space to squeeze the plug thru. once my ballast goes out, ill try it and see.
12-22-22, 10:31 AM
#10
Got my ballast and bulb in- success
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