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Join Date: Apr 2007
Location: Walnut Creek, CA
Posts: 20
Left Front Headlight - Repeated Burnout - 1989 Carrera 3.2

Good new bulbs, (Currently Heliolite 9004 - Halogen) keep burning out, though handled correctly.
History in last 8-9 months between 93,000 and 98,000 miles is:

Left bulb - low beam burned out & replaced
Dipper switch portion for low beams failed and took down both bulbs
All parts replaced
Replacement dipper switch, portions for both high and low beams failed, initially low then high beams, taking down both bulbs
All parts replaced
Both bulbs again failed
Relay kit added for protection
Left bulb low beam then failed and was replaced
Last night bulb for high and low beam elements failed.

I do a lot of two lane road mountain driving, where headlights are useful.

Any suggestions appreciated.

Old 01-13-2008, 01:12 PM
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Location: So. Calif.
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Bulb brand? I'm not familiar with Heliolite 9004, but what do I know? Bad batch is possible. Try another source/brand.

Handled correctly? As in, "used cotton gloves or equiv. so no skin oil transfer to glasss"? Clean with rubbing alcohol before installation?

Check charging voltage at the battery. Should be no more than 14.5V max.

Sherwood
Old 01-14-2008, 12:27 AM
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Left Headlight assembly loose?..vibration..
Old 01-14-2008, 02:41 AM
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Quote:
Originally Posted by 911pcars View Post

Check charging voltage at the battery. Should be no more than 14.5V max.
Good sug. A voltage spike can wipe out a bulb in a heartbeat. Also check for a good clean ground to the lights. A poor ground will cause high resistance for the bulb.
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Old 01-14-2008, 02:52 AM
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I also agree about the charging voltage. A slightly higher voltage can drastically shorten bulb life but is not likely to cause both bulbs to fail at the same time. I would guess either faulty bulbs or a voltage surge in the charging system from a bad votage regulator or faulty connection.
Old 01-14-2008, 07:32 AM
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Thanks everybody for the rapid responses, and good suggestions. Voltage held at 14.35 when measured at 2200 rpms, however a spike could be the explanation, though I'm not sure how to test for it. Meanwhile, I will check all the connections.

Is the ground for the headlight just a wire to the bucket, the frame or what should I look for?

Old 01-14-2008, 01:18 PM
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