Replaced HID Ballast, now no high beam

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by ack714, Feb 28, 2016.

  1. ack714

    ack714 Junior Member

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    Hello all, recently I removed my headlight assembly and successfully replaced the HID ballast. Unfortunately since the repair the high beam no longer engages. In order to pass inspection in VA it needs to work properly. I wanted to ask for any input from the forum on what I should check for before I removed the assembly again. Id like to be prepared so I can reassemble the same afternoon.
    Thanks for your help.

    Rob
     
  2. Patrick Wong

    Patrick Wong DIY Enthusiast

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    For HID headlights, the high vs. low beam pattern is produced by a mirror in the headlight assembly which controls the amount of light cast in the upper portion of the light pattern. If the high beam pattern is not working on one side, that would imply that the wiring harness connector to the motor that moves the mirror is loose or that the motor has failed.
     
  3. ack714

    ack714 Junior Member

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    Thanks Patrick. I'll check the wiring. I also changed the bulbs when I did the work. Ill troubleshoot soon.
     
  4. eagsc7

    eagsc7 Geocacher

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    Is there a part number for the mirror motor? "...would imply that the wiring harness connector to the motor that moves the mirror is loose or that the motor has failed. "
     
  5. eagsc7

    eagsc7 Geocacher

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    And to that point, When I switch to High Beams the HID Bulb turns off. Shouldn't it actually stay on? I've checked the Bulb, switch(via wiring checks), Fuses, and Think its the motor now. Anyone have schematics or diagrams of the HID Headlights on the 05 -09 Prius?

    Thanks!
     
  6. jm98

    jm98 Member

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    I have same situation with cheap replacement HID. High beam does not work. I am wondering if it's by design.

    [​IMG]
     
  7. eagsc7

    eagsc7 Geocacher

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    I didn't go with the "Cheap" HID Bulbs... Over $100 PER Freaking Bulb! Just sayin...
     
  8. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    It's not a motor, it is a solendoid. It just moves a little shield back and that makes it a high beam in the Prius. And yes the high beams stay on the entire time.

    Each side is fused independently so you can check just that one fuse. Also, if you don't seat the bulb perfectly, it can jam on the shield and the reflector won't work. If you misaligned it in such a way that the arc return is being shorted to the reflector housing (ground), then yeah it will turn off by faulting the ballast (BAD!).

    Also the notches in the bulb have to align just right with the notches on the reflector so when the solenoid pushes it moves. Some bulbs the notch is too big nothing moves. Sometimes the notch is too small, it catches and dies.

    $100 per bulb is average, not cheap and not expensive. But the aftermarket copycats are fully aware of the mentality of you get what you pay for and are trying very hard to make that not true. They will take their crap bulbs they sell for $20 and just list them as $100. Same exact thing, but at $100/bulb it has to be genuine right? Wrong.

    If your bulbs aren't genuine Phillips or Osram or GE, etc, it is likely to be one of these quality control type issues with the bulb. If the notch is too small, some time with a file carefully making sure not to touch the glass or get shavings stuck anywhere will work. The other big one is just human error in installation. Oil from humans on the bulb will kill the bulb in months versus many years.
     
    dowid and Danny Tamburrino like this.
  9. Danny Tamburrino

    Danny Tamburrino New Member

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    Patrick Wong .. thanks for sharing this it’s NOT documented in the owners manual!!
    Haven’t researched on Mitchell’s Database Repair yet!
    -
    I had replaced the right HID bulb, and for some reason the high beam wouldn’t work!
    It’s fixed now .. either a bad connection at the head lamp assembly or bulb not quite positioned correctly. Service manager local dealer was trying to tell me that there’s a separate bulb for high beams
    -
    Anyway I’ve been in the automotive business all my life!! .. this is a new one for me!!
    The Toyota parts illustration shows the mirror motor and ballast available separately!
    Danny Tamburrino
    Auto Milano (on Facebook)
    San Rafael, California
     
  10. dowid

    dowid New Member

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    Do you know where is this solenoid located ?

    I am having the same issue with high beam not working on driver side. checked fuse, replaced HID bulb and ballast. no success.
    The official Toyota dealer after 100$ diagnostic suggested to replace headlight assembly for 600$. I can find aftermarket head light assembly for 200$ on eBay. Just interested if it's something inside the headlight that can be replaced without changing whole headlight assembly.
     
  11. dowid

    dowid New Member

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    Looks like I found the solenoid on ebay. OEM-06-09-Toyota-Prius-Xenon-Headlight-High-Beam-Solenoid-D4R-Bulb-Retainer-Clip (can't post url because of newly registered user)
    solenoid.jpg

    still looking for original OEM part number since it's out of stock on ebay
     
  12. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    It is inside the headlamp assembly and it is officially not repairable.

    Of course it is with enough determination and time, but that's not how automotive repair works in 2021.

    To open the headlight assembly you have to bake it in an oven to free the adhesive sealant around the entire thing. Then you can pry it apart and access the reflectors and the actuator. To put it back together again, you can reuse the old sealant and bake it back, but always better to use new sealant. This is not that easy and there is a high risk of deforming/destroying the housing in the process.

    If your low beam is working there was absolutely no reason to replace the ballast or the low beam. That is just wasted money.

    It would be easier and cheaper if you value your time to get a used headlight assembly from a 2006-2009 Prius and put it in. The solenoid rarely fails unless you're constantly flipping it on and off which you shouldn't be doing anyways or if something happened like it was in an accident or water got in there. Meaning almost all the used ones you can find on eBay, will work just fine.
     
  13. Priusyipee

    Priusyipee Active Member

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    Would the solenoid from a 2004 - 2005 HID system work? You would have to change the connector. IMG_20210113_180416591~2.jpg
     
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