On my '99, I'm going through left headlight bulbs about once every two weeks or so. I have yet to replace a right one. The bottom of both headlight lenses have been drilled through b/c they were both collecting water. Also, the left one got hit by a rock, and had a small pencil size hole in the bottom... I've since glued a piece of clear plastic over the hole in the lens to "seal it up". Regardless, I keep blowing bulbs.... not sure why.

Any ideas?

 

Hey Andy, you need to be hang around more often. If it were me I would be checkin for any corrosion in the receptacle and if it's clean you almost have to have a break in the wire someplace that's causin a short. Not much else to go wrong with headlights. Battery and ground to the switch, then from there to the lamp and that's pretty much the whole circuit. A broken or corroded wire could cause amperage differences being sent to the bulb and killin it is what I'm thinkin here.

Give me a minute to do a search and I'll post it here for a new replacement set of high output wires that put out more light then the factory wires anyway along with taking the load off the switch which is a known weakness in these trucks anyway.

Here ya go. https://www.dieselbombers.com/5-9l-2...t-harness.html

 

Ahhhhh Hello again my wise friend!

yeah, I should be around here more often. I've been a fixin' up a "old" (2000) Yamaha YZ250. She's been a long project, but I finally got her in the dirt this past weekend. Dang... that thing is FAST.

But I digress... So yeah, that harness is EXACTLY what I need. I've had crappy lighting for years, and have planned to do the sport headlight conversion, but have never gotten around to it. I had also thought about adding some relays and pumping 12v directly to the lights... but this harness will save me all that trouble!!! WHOO HOO!!

Thanks man!
Andy

 

Now let me know when you figure out how to keep the moisture out of that headlight housing. One a mines been doin for years and I can't get it to seal right no matter what I try.

 

I took the black upper bumper cover off, and then drilled two really small holes in the bottom of each lens. Haven't had any water/condensation issues since.

(of course, this is probably why I'm having problems now...)

 

are you touching the bulb itself at any time when putting the new light in? even bumping it on your hand or anything? Doing that will get oils from your body onto the light and cause it to burn out/blow up very prematurely.

 

what he said^^^

 

Well, the first few I changed, I wore nitrile gloves for that very reason.. After that, I quit wearing the gloves, and they seemed to last about the same ammount of time.

 

oh....well, hmmm im outta ideas then