Headlight assembly replacement

Discussion in 'Gen 2 Prius Accessories & Modifications' started by sundy58, Jul 28, 2019.

  1. sundy58

    sundy58 Junior Member

    Joined:
    Dec 28, 2008
    16
    0
    11
    Location:
    Donna, TX
    Vehicle:
    2008 Prius
    Model:
    Two
    We had a fender bender in a parking lot, the front bumper cover damaged and drivers side headlight has a crack. We have a 2008 Touring so we have HID, and have had an intermittent headlight since we got the car. I would like some advice for new headlight assemblies. We are on a budget so $600 and above projectors are not an option. I like these halogen assemblies; LumenĀ® - Toyota Prius with Factory Halogen Headlights 2008 Black Factory Style Headlights to use with LED bulbs.

    I am an electronics guy so I can figure out the relay to enable Hi/Low beams. Any advice or experience you would like to share is welcome.
     
  2. caravan2429

    caravan2429 Junior Member

    Joined:
    Sep 21, 2018
    62
    18
    0
    Location:
    Sandy, UT
    Vehicle:
    2007 Prius
    Model:
    II
    I'm not sure if HID wiring harness is same as halogen one. I have heard of some HID issues with gen 2, and I think you are on the right way. It's easier and compatible with halogen assembly. I'm using LED bulbs on my halogen housing, and I'm satisfied with the result.
     
  3. RobH

    RobH Senior Member

    Joined:
    Sep 18, 2006
    2,359
    946
    69
    Location:
    Sunnyvale, California
    Vehicle:
    2006 Prius
    I replaced my 2006 HID headlight assembly with an aftermarket one from eBay - Fits Toyota Prius 06-09 Drivers HID Type Headlight Assembly 81185-47170 | eBay

    Cost about $220.

    The non-HID ones are much cheaper. You may be able to remove the lens from a non-HID assembly and install it on your HID unit. See projector conversion sites for how to do that. Just cook the entire assembly in the oven for about 10 minutes and the glue loosens enough to remove the lens. Unscrew the level adjustment mechanism to get clearance for removal of the wire from the ballast to the bulb.

    Intermittent operation is the failure mode for worn out HID bulbs. Small chance that the ballast is bad, but not likely. The bulbs that work are Phillips or Toyota brand. If a bulb costs less than $50 retail, it's probably junk and will fail in weeks or a few months. Or you could pay full fare and get a counterfeit. If anyone has good experience with cheaper bulbs, please speak up.
     
  4. sundy58

    sundy58 Junior Member

    Joined:
    Dec 28, 2008
    16
    0
    11
    Location:
    Donna, TX
    Vehicle:
    2008 Prius
    Model:
    Two
    Yes I have read many threads on the HID headlights and the wiring is different. I'm pretty sure a relay triggered by the voltages from the HID wiring will give me the Hi/Low action needed.
     
  5. sundy58

    sundy58 Junior Member

    Joined:
    Dec 28, 2008
    16
    0
    11
    Location:
    Donna, TX
    Vehicle:
    2008 Prius
    Model:
    Two
     
  6. sundy58

    sundy58 Junior Member

    Joined:
    Dec 28, 2008
    16
    0
    11
    Location:
    Donna, TX
    Vehicle:
    2008 Prius
    Model:
    Two
    This is the wife's car and she is ready to change the look of the Prius. We are going with black accents to the lower portion of the car, so the black headlight housing would be part of the theme.

    We have had trouble with the passenger side headlight from the beginning. Toyota replaced a bulb under warranty, I have replaced the bulb and even with a new bulb in it, it is still intermittent. It is possible it is the wiring harness and I don't want to run down an intermittent open in the wiring harness. I would rather wire around it. Of course now that I say that I realize it is a method to stay with HID and not go to halogen assembly with LED bulbs. I need to inspect the housing closely to see if it is just the lens of if the damage goes deeper.
     
  7. RobH

    RobH Senior Member

    Joined:
    Sep 18, 2006
    2,359
    946
    69
    Location:
    Sunnyvale, California
    Vehicle:
    2006 Prius
    The next step would be to replace the ballast on the right side. And another bulb, since it is behaving like a defective bulb. Changing to a halogen assembly is a lot more work than troubleshooting the HID assembly you have.
     
  8. SFO

    SFO Senior Member

    Joined:
    Feb 7, 2017
    2,413
    2,698
    0
    Location:
    Northern California
    Vehicle:
    2007 Prius
    Model:
    N/A
    After rereading this informative thread, I went ahead and purchased a pair of cheaper 4300K D4C bulbs for $12 including shipping. Even with 100 hrs of usage, these are still holding together and no one has flashed me for not installing the D4R bulbs. The bulbs seem slightly brighter overall, and no longer go out intermittently.
     
    RobH and Raytheeagle like this.
Loading...