Problem Replacing H5 Bulb

[jyl]

While attempting to replace the stock bulbs in my H5s with 100/80w bulbs sourced from Pelican (yes, I have installed the Sucro relay kit) I ran into a problem. The bulb (PEL-H5-80100, found at the bottom of page 7 in the "Light Bulbs" section of the Pelican site for the Carreras) has welded itself onto the socket.

OK, I know a photo would help here but I don't have my digital camera handy so I'll use words. The bulb comes in a black plastic holder. That holder slides into a gray plastic socket that fastens (bayonet-style, push and turn) into the back of the reflector. Then you use the bulb retainer (928-631-960-00) to secure the bulb in the socket. What has happened is adjacent parts of the black plastic bulb holder and gray plastic socket have melted together. So the bulb cannot be removed from the socket. I've tried prying and cutting - no can do - they are effectively welded together. The socket comes out of the reflector just fine, I had to do that to clean the inside of the lense and the reflector surface with isopropyl alcohol.

Where can I get the gray plastic socket? Pelican doesn't list it as a separate part. I have a bad feeling it is sold as part of the lense/reflector assembly (C-631-909-00) and I don't want to spend $135 for that. This was supposed to be an inexpensive way to get better light - I'm too cheap to get H4s without trying this first. Any ideas?

For now, I guess I'll get to compare the left headlight with the new 100/80w bulb with the right headlight with the old stock bulb (45/65w, I assume). After I dry out the headlights.

P.S. No-one needs to point out that this job is rated for difficulty as just above putting air in your tires.

[jmohn]

If I understand correctly, what you need is the socket plug. Try this link:
http://www.pelicanparts.com/catalog/shopcart/911M/POR_911M_lenses_pg2.htm

part number: 165-941-165

Good luck,

Jerry M
'78 SC

[RoninLB]

Originally posted by jyl
Any ideas?

yeah.. I have an idea.. the idea, based on you taking the lights seriously, screw the H-5 into the garbage.. cause you will not be happy w/DOT lens....................Ron

[john walker's workshop]

they do melt together quite a lot. all you can do is go carefully when you crack snap, and chip away the remains, because if you break off the socket that's attached to the reflector, it's $$ time.

[schulr]

I am getting ready to install the same H5 bulbs in my 87 too and would like to avoid the melting issues. How do you avoid this, if at all?

Bob

[jyl]

OK, I'll have another try at cutting them apart.

I'm thinking that the new 80/100w bulbs may be the last bulb change these lights ever get. Because if they got hot enough to melt together before . . .

[RoninLB]

Originally posted by jyl
OK, I'll have another try at cutting them apart.

I'm thinking that the new 80/100w bulbs may be the last bulb change these lights ever get. Because if they got hot enough to melt together before . . .

can I finish your sentence

... starting a fire

.. maybe there is a heavy duty bulb socket around.. maybe at the "off road" truck/SUV stores. 80/100w real bulbs is big heat for stock set ups.. at least give it periodic inspections..........Ron

[jyl]

Got it. Had to use a Dremel, drill a bunch of holes in the melted-together areas, and cut the bulb out of the socket. Not very pretty but looks like I've saved myself $135. Still drying out the headlights, though.

Am worried about the four-letter word - "fire". Surely Pelican wouldn't sell 100/80w bulbs for H5s if they're dangerous? Hmm - will run them for a while and recheck. Will also avoid running high beams for long periods.

Edit: All done. Thanks everyone. Whew! Maybe next week I'll tackle adding air to the tires.

[masraum]

If you need to can run your high beams for long periods of time maybe it's time to invest in driving lights.

Personally I would like some driving lights.

[jyl]

Driving lights would be nice. But with the foglights integrated in the valence (this is a 1989), l don't have a lot of options, or do l?