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General E46 Forum
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Old 11-17-2012, 09:04 AM   #1
VECTOR
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Join Date: Mar 2010
Location: S Florida
Posts: 236
My Ride: 2004 330CI auto vert
Question Anyone Experience Melted Headlight Wires?

My right front headlight went out some time ago. Originally I just figured it needed a replacement bulb, but the mechanic said the wires were fused/melted together to the point of needing a new housing.
I took it to another place that specializes in BMW's, and they said they could probably fix/repair the wires. As it turns out they said they were unable to fix it.
They also said this is a common problem they see among BMW's with Bi-Xenon Adaptive headlights like mine.

Considering the cost of replacing the entire housing and possibly other components like the ignitor, ballast, D2(?) and bulb, how does anyone other than the uber rich deal with such an issue? I mean they are talking about at least $1,000 & probably more to replace it, which is

Last edited by VECTOR; 11-17-2012 at 09:06 AM.
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Old 11-17-2012, 04:26 PM   #2
jayb328i
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Join Date: Jan 2012
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Hard to believe that it cannot be fixed. If you were closer to me, I would have a go at it. Just because they said they could not fix may just mean they are unable, unwilling, do not know how, do not have the material or time.
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Old 11-17-2012, 04:46 PM   #3
VECTOR
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My Ride: 2004 330CI auto vert
I wish you were closer as well. Want two 50 yard line tickets to the Dolphins vs. Seahawks game this coming Sunday in exchange for the repair?

I brought it to them specifically because they said they have experience fixing this problem. However several guys in the shop said it was too far into the housing to get at since all the wires were melted/fused together.
They did not charge me for the attempt even though they had at least an hour into it. Nor did they try to talk me into getting it repaired with new parts. The owner even said he would lay out that type of money.
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Old 11-17-2012, 05:20 PM   #4
jayb328i
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you can always look at a junk yard or someone parting out parts on this site.
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