Headlight problem

Toyota replaced both my headlight bulbs today. The dealer said that there was a service bulletin out on it (T-SB-0030-08). They used #90981-20015 bulbs. It must be a very common problem as even the courtesy van drivers were aware of it.

Copy:
T-SB-0030-08 Rev1 April 11, 2008
HID Headlight System - Diagnostic Tips
Service
Category Vehicle Exterior
Section Lighting (ext) Market USA
Applicability
YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2004 – 2008 Prius
TSB REVISION NOTICE
• May 12, 2008 Rev1: The part numbers referenced in the Note at the end of the Repair Procedure
have been corrected.
Any previous printed versions of this service bulletin should be discarded.
Introduction
The following bulletin is a supplement to the Repair Manual and provides diagnostics tips for
troubleshooting “Low Beam Does Not Turn On (One Side)â€.
Parts Information
MODEL YEAR CURRENT PART NUMBER PART NAME QTY
2004 – 2005 90981-20007 1
2006 – 2008 90981-20015
Bulb, Discharge Headlamp
1
Warranty Information
OP CODE DESCRIPTION TIME OFP T1 T2
N/A Not Applicable to Warranty – – – –
© 2008 Toyota Motor Sales, USA Page 1 of 2
T-SB-0030-08 Rev1 April 11, 2008 Page 2 of 2
HID Headlight System - Diagnostic Tips
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST’S) PART NUMBER QTY
Digital Multimeter
(or Digital Volt Ohm Meter [DVOM] or Equivalent) 09082-00050 1
Terminal Gauge Set* 00002-48937-01 1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Repair Procedure
NOTE
If both low beam lights will NOT turn on, refer to the Repair Manual for diagnostics.
1. Using the SST or DVOM or equivalent, perform a voltage drop across connector H5/H3 pins 1
and 2.
SST P/N 09082-00050 or equivalent
• If reading is equal to source voltage, proceed to step 2.
• If reading is NOT equal to source voltage, isolate and repair the trouble area in the headlight
assembly power supply circuit.
2. Using the SST, check the pin fit of the 12V connector at the HID ECU.
SST P/N 00002-48937-01
• If pin fit is good, proceed to step 3.
• If pin fit is loose, repair or replace the connector and harness.
3. Switch the HID bulb between the left and right side.
• If the condition follows the HID bulb, replace the HID bulb.
• If the condition does NOT follow the bulb, replace the HID ECU.
NOTE
• The HID bulb and HID ECU service parts for 2004 – 2005 model year are NOT compatible
with 2006 and later model year vehicles. Installing a 2004 or 2005 model year HID
Bulb or HID ECU on a 2006 or later model year vehicle may cause an intermittent
operation/flickering of the HID bulb.
• In most cases, when replacing the HID bulb, the HID ECU does NOT need to be replaced.
In the event of HID ECU replacement, order the following part numbers: 81107-51050 (2004
– 2005 model year) or 81107-47150 (2006 – 2008 model year).
© 2008 Toyota Motor Sales, USA

 

It has been said before, by me (possibly on this thread for all I know) and others:
There is NO reason to pull the bumper off to replace the headlight bulbs.

It isn't necessarily EASY due to the lack of room for your hands, but you can do it from inside the engine compartment in about 10 minutes after you do it slowly the first time to figure out what needs to be done. The most you have to disassemble is the air duct in front of the washer fluid reservoir and all that entails popping 2 of the plastic push fasteners. On the driver's side you can get a little extra room by removing the fuse box cover.

 

Gremlins?

 

I can't believe they are not having a recall. I'm joining the club at 49,800 miles. The right side was replaced due to a hit and run. the left side is failing intermittently.
Thank you PRIUS CHAT for the info!!!
I filed with NHTSA and will be calling the dealer tomorrow about my repair!

 

I was having this headlight problem. Fortunately I was still under the original warranty. (33,000 miles.) The dealership I purchased the car at just ordered me new HID's and everything seems to be fine.

 

I've been reading this topic for 18 months since I got pissed off at the toyota dealer. They wanted over 700 bucks for the two lights. So being pissed off for 18 months I drove around with one hand on the light switch while drive at night. I went to ebay as instructed on this site and purchased 2 lights from XEquipped@EBAY..

Stan Didenko
The price a whopping 88 bucks delivered to my door! I put them in and both worked. However after 3 hours the drivers side went out and I emailed stan and he said send the bad one back and I will send a new one. 10 days later the replacement came and has been working for 1 week. Toyota really dropped the ball on this one.


Thanks to this forum I saved over 600 bucks!!!

 

I've been reading this topic for the past 7 months which is when I noticed the same problem with my 2006 Prius - driver's side headlight failing intermittently. I took my car to the Toyota dealer in May '08 and they said the sensor was defective and for $500 they could replace it. My car had 36k (past warranty), so I decided to wait. A month later I was in a car accident by an uninsured driver (side swiped) in the night time. The insurance company determined it was not my fault and paid over $5,000 for the repairs - which included replacing the leveler sensor attached to the rear axle. Unfortunately, this did not correct the headlight problem - which continues to fail; I was stopped by the police two days ago who issued me a warning about my headlight. I've reported this incident to the Toyota '800 number' and filed a complaint with the NHTSA. I'm hoping that the accident (which may have been caused by the defective headlight), will prompt a formal investigation and instigate a recall for the headlight controllers. I'll keep everyone posted if anything becomes of this.

 

suebeegrl,

Your dealer is either clueless or a greedy BS'er. The sensor he claimed was defective has nothing to do with your HID headlights failing (turning off) intermittently. What a bad sensor usually does is tip the headlight aim way to low so you can only see about 20 feet ahead of you (but sometimes way too high) & either condition can happen without seeing any warning lights on the dash.

Ken (in Bolton,Ct)

 

I have the same intermittent problem with the HID headlight on the drivers side. The dealer thinks replacing the bulb might help but......It does not appear to be connection related but a problem in the bulb or control circuits? I will contact Toyota and the national safety board.

Twhittak

 

My dealer in Easton PA just replaced both bulbs - no charge! This is Dick Milham Toyota. Maybe give them a buzz and inquire as to their reasons for the free replacement - then tell your dealer.

 

Dealer replaced the driver's side headlight bulb and told me that they had called Toyota and found that Toyota was aware of the problem. Dealer hinted to me that I should contact Toyota and ask for a reimbursement of the nearly $400 cost to replace the bulb.
I called Toyota and expressed by disappointment in their lack of quality and the danger created by the defective bulb. Wrote them too.
They agreed to reimburse me.

Suggest others do the same.

 

I had the same issue with my HID and yes I have an '06 pkg.6. There is a lot posted on this and for me the dealer replaced, under warranty, the HID bulb. After over 1 year, the problem has not come back.

 

Another tid bit for the drivers side bulb:
Trick! After popping the fuse cover, you may want to remove the blue and green relays.. it will give your hand more room and thus more power! Steady pressure once it starts moving, when it stops.. wiggle it so it will pop loose.

 

I have joined the headlight club as well. 2006 Prius, 42k miles. Passenger side light going out, can turn it back on, but will go out again. Took it to the dealership, was told "it's not out now, costs $1200 to replace, wait 'til it's a real problem'. I got pulled over for a headlight out a few days later, that's what I call a real problem!

I took it back to the dealership, the woman booking me in said "oh, yeah, we see that problem with the Prius". When I asked what "that problem" is, she said just what you report, intermittent headlight outages. I asked if it would be covered & she said "I'll see what I can do for you". Ultimately, both headlights and both computers were changed at no cost to me. Written on the invoice was "Goodwill for owner loyalty". I think it should have read "we better cover this one 'cause this lady is gonna make a big noise if we don't."

I reported to NHTSA as well, maybe we can all get together & force a recall...

 

Goodwill... aren't they so nice!..... I can just bet you that if Toyota didn't pay for it.. there would be "no" goodwill!

Maybe it would behoove someone to print off all 295 posts on the subject to bring in.

 

Just wanted to join the drivers side "possessed headlight" club. I've been reading this thread for quite some time since a few months ago somebody told me my left front headlight was out, but of course when I went to look myself or show others - tada! Both lights stay on. I have an appointment with a yota dealership this week (not where I purchased it though) and was told I was "lucky" because my car is still under warranty (it will expire later this month when I hit 36,000)

Is there anything I should be telling the dealer specifically? Or should I just assume that he knows what this problem is? He told me they will replace both front headlights which should correct the problem. I've already reported it to the NHTSA and plan to call Toyota as well...It is unbelievable to me that a recall has yet to happen since there are hundreds of us with this problem! Guh!!

 

Add me to the group as well. My wife noticed the driver side was out when we were in traffic the other day. I've got an 06 with 60k on it. It goes out from time to time and I just turn them off and back on and then they're both all set. I've now read through a bunch of threads here seeing that this is a common problem. I've got an oil change coming up and I'll see how well I'm treated when I bring it to their attention.

 

Add me to the list. I have a 2007 and my driver side light is going out intermitently. Turn off and back on and the light works. Of course I have 37,000 miles but I do have the extended waranty.

Dealer said they were unaware of any headlight problem.

Guess I need to call Toyota also.

Greg

 

Adding my 2007 Package 5 to the mix. I've had the problem with both of my headlights. I'm taking my car in to the local dealership tomorrow morning to have them deal with this issue.

I'm definitely relieved to know that I am not the only person with this issue. Thank goodness for these forums! :rockon:

 

I don't think there are any Toyota dealers that haven't heard of this problem. That's incredible that they would even try to get you to believe that. I'd print out a bunch of the posts and toss them on his desk and tell him that he's heard about it now!

Dave