Perplexing Morimoto HID Retrofit Kit Issue

GEORocks · August 18, 2018

Will do my best to keep this brief but could really use the board’s help here.

Buddy and I both have ‘15 Silverado 1500 LTZs wit halogen projectors. In June of ‘17 we got together and upgraded both headlight systems to the Morimoto XB35 system with 5500k bulbs and 35W ballasts - a common setup I understand. Everything was awesome for a full year.

Then about a month ago my buddy calls to tell me his passenger light is flickering at high frequency when he starts his car. 2 days later he calls to tell me it is out all together. Later that same day, my passenger side starts blinking on start up as well. Then 2 days later it is out as well. Weird. It gets weirder.

We complete the trouble shooting procedure and believe we’ve isolated both issues to passenger side ballasts (we swapped ballasts and the lights returned immediately). The seller (TRS) processes warranty replacements for both of us and we install them a few days later - no issues; problem solved we thought. But:

3 days later my buddy calls me again to advise that his passenger side is out again. Later that same day, mine is out as well. We get together that evening to put some real effort to isolating the issue and while we were able to - yet again - isolate the symptom to the passenger side ballast, we went further to verify that there wasn’t another component in-line on the passenger side that was causing the ballast to fail. We did this by leaving the driver’s side ballast on the passenger side. Sure enough, the next day the passenger side low beam failed again for both of us.

I work in subsea oil & gas and have some smart electrical systems dudes at my disposal. I asked a couple of them to have a look at the wiring skematic. They both concluded it was likely the capacitor or relay. I called the seller and explained - but they felt it was much more likely that the ignitor immediately downstream of the passenger ballast was fouled and backfeeding into the ballast, causing it to fail. So TRS sent two new ballasts and an ignitor for the passenger side. I received them yesterday afternoon and immediately installed them. Everything came on as designed . Awesome! But: 20 minutes later, yet again the passenger side bulb was out.

I have checked the grounds, connections, and power (on the dash). I am quickly losing patience with this statistically improbable issue but have no ideas at this point other than to replace the passenger side relay. The capacitor is a central component and would assume it would affect both sides.

My my buddy is sitting on the sidelines waiting to implement whatever solution works for my vehicle. FWIW, TRS is of the opinion they are not the same issue.

Having said all all of that, I throw myself to the hounds here and ask for any and all perspective. Where I am at right now is a phone call to TRS on Monday requesting they replace the ENTIRE system and I will install it again. If LEDs were viable in these projectors I would be all over it.

Very much appreciate any help. This is my first post as well. I used to be a member of JeepsUnlimited and had forgotten how much I missed being involved in an auto forum until I began reading through the threads here.

silveradosid · August 19, 2018

so you are saying there is only one capacitor for both headlights

GEORocks · August 19, 2018

9 minutes ago, silveradosid said:

so you are saying there is only one capacitor for both headlights

Yes; it provides an ‘anti-flicker’ function to the system. There are separate relays, ballasts, and ignitors for each side however.

silveradosid · August 20, 2018

i would say the capacitor cant handle the load of both lights, when i installed mine i put a capacitor on each light

truckguy82 · August 20, 2018

You could just end your problem all together and purchase a couple hylux ballasts. No additional pieces needed for canbus/antiflicker. It’s not a free solution but it’s less hassle.

cbrsilv15 · August 20, 2018

I'd check the complete HD relay harness. Unplug and reseat all the connections and clean all the terminals. It's weird that it keeps happening. Check the ground on the harness and make sure there's no dirt build up on it. I've had mine installed for a few years now with no issues, knock on wood.