Headlight issue and it's not the ballasts

B6/7 S4/RS4
#1

So my headlights are having issues. Especially the right one which keeps going out whenever I turn or hit some bumps.

I replaced both ballasts and the problem is still persisting. I don’t think it’s the bulbs as they don’t turn off if I’m just idling.

Anyone ever come across a problem with the swivel mechanism? I’m dreading replacing the entire headlights as those are not cheap.

#2

There was a problem with the 55 - headlight range module on certain B7s. There was a TSB for the problem and I think that there was a software update that had to be done. I never had to do that repair but a bunch of other techs at the dealership that I worked at constantly bitched about it.

#3

Axel, have you done that headlight switch mod that requires a copper wire to be jumped from one pin to another? I had the same problem you did, swapped the same parts and still had the issue. Then I decided to take a look at the switch. The copper wire had begun to unwind a bit and was periodically brushing up against the pin next to it (when hitting bumps in the road etc). Causing the headlight flicker and a whole bunch of other random annoying shit that had me scratching my head. Needless to say I undid that mod, problem solved.

#4

No, never touched anything related to head lights or the switch. Completely stock all the way through.

I feel like the mechanism is just weak and when it fully turns to one side or if I hit a bump, the mechanism shifts around (maybe even by less than a mm) and turns the projector light off. But that’s just a feeling. I have absolutely no evidence to back up that feeling and I couldn’t be 100% wrong lol.

#5

Had the same issue as described in the first post when I bought my car. Right headlight started to flicker and went out. After switching lights off and back on it worked until the first bump, then it flickered and went out again.

Replaced the bulbs and problem was gone. Aren’t the bulbs cheaper to replace as the first point of troubleshooting as I imagine the ballasts are expensive or?

#6

This isn’t the first time it’s happened and I’ve had to replace the ballasts each time and it fixed the problem every time. This time it didn’t though. The lights aren’t flickering much though. They just go out.

I’ll replace the bulbs next. See how that works out. I hate these complex mechanisms that weren’t fully thought out properly.

#7

I feel you. I never had issues with the lights on any of my cars so far and I already dread the day when it’s not just a dead bulb… :o

#8

Any chance you can copy and paste the copper wire mod over here for us to take a look at. I think a buddys car has this issue and I would like to see how others have fixed it

Axel did you fix this on your car yet

#9

Just saw this ^, haven’t been on in a while. Yes, I’ll take a look and see if I can find the thread with this mod and copy it here.

Edit:

Here is a link to the mod I was referring to;
http://www.audizine.com/forum/showthread.php/188467-a-Bit-longer-than-5-minute-Fogs-w-JUST-Parking-City-Lights?highlight=fatauto

#10

The new ballasts weren’t adaptive even though they were supposed to be. Pulled the fuse and it stopped dying. Still some flickering here and there on occasion so thinking the bulbs are dying.