[djmcmath]

I've been through this one twice with my H-4's (with Sucro relays). The first time, quickly replaced bulbs, didn't fix the problem. Spent several long hours troubleshooting with electrical diagram and multimeter, to no avail. Finally resolved to dismantle, clean, and rewire the entire headlight system start to finish -- and found that the problem had disappeared.

The second time was no better. I have no idea what part I jiggled, pulled on, cleaned, rewired, or magically corrected, that did the job -- I'm now convinced that it was my realization that I had been beaten and needed to rewire everything that did the job. .... So make a resolution to tear out all of the wires associated with the headlights and redo the whole thing, correctly. Get the tools and parts. Stage them in your trunk, where the wiring gremlins will be able to see them. If that doesn't fix the problem, I don't know what will.

Good luck,

Dan