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Thread: Headlight Wire Jackets Just Flake Off

  1. #26
    Join Date
    May 2010
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    dallas, tx
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    2008 Nissan Titan CC
    My car has been in Germany since about 10 months ago. I would assume the super cold snowy conditions there would cause the rubber, heatshrink, and any other coating to crack, peel, and flake. I guess it being kept refrigerated has helped it as most of the stuff i've noticed most of these flaking issues are in hot/humid climates.

    which worries me because i'm now stationed in Ft. Worth, Texas and goddamn if it's not hot/humid here like 9 months out of the year.

  2. #27
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    May 2010
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    USA
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    08 535xit
    some people have been coating their wires with liquid electrical tape as a precautionary measure.

    G~
    E61 Mods: Trailer Hitch/wiring, Cargo cover roller fix, Backup camera, H&R springs, ER charge Pipe, Mishimoto catch can, boost gauge, intake scoop, JB+, CSR Rear Spoiler, Full SAT retrofit.
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    E39 Mods: Euro dash conversion, Dinan exhaust, Dinan suspension with Camber kit, 2.81 differential, flappy paddle with double pull M mode activation/deactivation, backup camera, Video playback on Nav computer (iPod Video for video storage and playback), stereo video playback through DSP, MKIV computer, RPA Tire Pressure retrofit, Intravee II iPod integration, Euro armrest, HUD, Parrot BT, voice recognition module, trailer hitch/wiring, rear mounted 10" subwoofer with amplifier, lighted interior door handles, Evans coolant.

  3. #28
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    2008 Nissan Titan CC
    that's not a bad idea. i may end up doing that too

  4. #29
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    Oro Valley, AZ - USA
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    Damn, just went to replace the pass. side HID bulb on my (new to me) 2007 328iT and found all the wires in the headlight housing brittled and insulation falling off... Gheezh I haven't even registered the car yet, or made my first payment and now I'm faced with $3000 worth of headlights? I knew I shoulda stuck with E36's!

    What's the current DIY solution here?

    Both lights have yellowed and hazy lenses and non-working adaptive motors already, and I've got two new 4300K bulbs and ballasts sitting here, so is there an aftermarket housing out there that would come with new lenses, wiring harness etc for HID systems? I don't care about the adaptive portion and I'm I the process of getting the adaptive failure warning message coded out anyways; but man I just can't believe a burnt out headlight is now going to cause this much grief and cost. What a joke. Pulling the bumper and wheel liners now so I can get both lights out (yes you have to pull the whole fricking bumper to take out the housings).

  5. #30
    Join Date
    Jan 2017
    Location
    Florida
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    2007 328i
    Same situation here; bulbs have been replaced numerous times at dealership and at private Repair shops. No one mentioned insulation disintegration until the day light and high beam stopped working completely at same time. Quote for repair $2454.00. Ridiculous cost for something that should not have happened. Additionally, this is my only car that has the window trim that also disintegrated! Looking for a better option than spending $2500 for headlights on a 10 year old car valued at $4k! Anyone know someone in Orlando that can do this (besides a repair shop)?

  6. #31
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    Yup it's ludicrous... haha, mine has the totally destroyed upper windshield trim piece too. I've got older BMWs, all with good condition rubber trims...what's with the 2004- cars???

    Here's my link if you want to follow: http://www.bimmerforums.com/forum/sh...ase&p=29554303
    2006 R53 JCW (British Racing Green) - 1994 E31 840Ci 6spd (AVUS Blue)
    2021 F56 JCW (Rebel Green) - 2000 E38 740i Sport (Titanium Silver)
    2017 F26 X4 M40i (Carbon Black) - 2007 E91 328iT (Deep Green)
    2012 E82 135i M Sport (Marrakesh Brown) - 2015 E84 X1 (Cashmere Silver)
    2005 E53 X5 3.0i Sport (Kalahari Beige) - 2000 E36/7 M Roadster (Oxford Green)
    2000 E38 740i Sport (Oxford Green) - 1999 E36 M3 Coupe (Fern Green)
    1995 E31 840Ci Canadian (Oxford Green) - 2000 E36/8 M Coupe (Oxford Green)
    2004 E46 330Ci (Oxford Green) - 2001 E36/8 Z3 3.0i Coupe (Oxford Green)
    2002 E39 525i Sport (Oxford Green) - 2002 E36/7 M Roadster (Oxford Green)
    2001 E53 X5 3.0i Sport (Oxford Green) - 2007 E63 M6 (Silver Grey)
    1995 E31 840Ci (Oxford Green) - 2006 E86 M Coupe (Sepang Bronze)
    2001 E39 530i Sport (Aspen Silver) - 2009 E92 M3 (Space Grey)
    2001 E38 740i Sport (Sahara Beige) - 2008 E92 M3 (Melbourne Red)
    2000 E38 740i Sport Canadian (Sahara Beige) - 1997 E31 850Ci (Jet Black)

  7. #32
    Join Date
    Dec 2010
    Location
    Crestview,Florida Panhndl
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    My Cars
    E60 535i M-Sport
    It's a bad situation, but not that big a deal to fix...if you are okay with electronics work.

    i had the same issue on my 2006 e46, bare wires(!), and I replaced the connectors with these: https://smile.amazon.com/gp/product/...?ie=UTF8&psc=1

    i basically pulled the headlight out and fished the new connectors through, soldered and heat shrinked them, and reassembled. An afternoon of work, but they are holding up very nicely.

    // Radar //

  8. #33
    Join Date
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    Oro Valley, AZ - USA
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    Those are a nice solution for the H7 bulb connection, but in my HID Xenon adaptive housings there are multiple wiring harnesses; for low beams, high beams, halos, HID ballasts, adaptive control modules, adaptive control hardware, etc.... All of those wires are compromised as well as they use the same crappy insulation. No way in hell I'm going to try to source connectors and pins to redo that mess on a 10 year old pair of headlights. So I ponied up and bought new housings, bulbs, ballasts and one control module. I'm right at about $1300 for the full overhaul...
    Last edited by Chamberlin; 01-18-2017 at 10:03 AM.
    2006 R53 JCW (British Racing Green) - 1994 E31 840Ci 6spd (AVUS Blue)
    2021 F56 JCW (Rebel Green) - 2000 E38 740i Sport (Titanium Silver)
    2017 F26 X4 M40i (Carbon Black) - 2007 E91 328iT (Deep Green)
    2012 E82 135i M Sport (Marrakesh Brown) - 2015 E84 X1 (Cashmere Silver)
    2005 E53 X5 3.0i Sport (Kalahari Beige) - 2000 E36/7 M Roadster (Oxford Green)
    2000 E38 740i Sport (Oxford Green) - 1999 E36 M3 Coupe (Fern Green)
    1995 E31 840Ci Canadian (Oxford Green) - 2000 E36/8 M Coupe (Oxford Green)
    2004 E46 330Ci (Oxford Green) - 2001 E36/8 Z3 3.0i Coupe (Oxford Green)
    2002 E39 525i Sport (Oxford Green) - 2002 E36/7 M Roadster (Oxford Green)
    2001 E53 X5 3.0i Sport (Oxford Green) - 2007 E63 M6 (Silver Grey)
    1995 E31 840Ci (Oxford Green) - 2006 E86 M Coupe (Sepang Bronze)
    2001 E39 530i Sport (Aspen Silver) - 2009 E92 M3 (Space Grey)
    2001 E38 740i Sport (Sahara Beige) - 2008 E92 M3 (Melbourne Red)
    2000 E38 740i Sport Canadian (Sahara Beige) - 1997 E31 850Ci (Jet Black)

  9. #34
    Join Date
    Dec 2010
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    Crestview,Florida Panhndl
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    139
    My Cars
    E60 535i M-Sport
    Wow! Okay, didn't realize all that...I've had my e60 for a little over a week and haven't held my breath and looked in the headlight openings yet.
    Thanks for correcting me, hate for someone to think that ^^^ will fix it.

    // Radar //

  10. #35
    Join Date
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    Oro Valley, AZ - USA
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    see my signature
    No probs Radar... If you want to see what kind of headlight issues E9x guys deal with, take a look at my E91 thread here: http://www.bimmerforums.com/forum/sh...ewest-purchase
    2006 R53 JCW (British Racing Green) - 1994 E31 840Ci 6spd (AVUS Blue)
    2021 F56 JCW (Rebel Green) - 2000 E38 740i Sport (Titanium Silver)
    2017 F26 X4 M40i (Carbon Black) - 2007 E91 328iT (Deep Green)
    2012 E82 135i M Sport (Marrakesh Brown) - 2015 E84 X1 (Cashmere Silver)
    2005 E53 X5 3.0i Sport (Kalahari Beige) - 2000 E36/7 M Roadster (Oxford Green)
    2000 E38 740i Sport (Oxford Green) - 1999 E36 M3 Coupe (Fern Green)
    1995 E31 840Ci Canadian (Oxford Green) - 2000 E36/8 M Coupe (Oxford Green)
    2004 E46 330Ci (Oxford Green) - 2001 E36/8 Z3 3.0i Coupe (Oxford Green)
    2002 E39 525i Sport (Oxford Green) - 2002 E36/7 M Roadster (Oxford Green)
    2001 E53 X5 3.0i Sport (Oxford Green) - 2007 E63 M6 (Silver Grey)
    1995 E31 840Ci (Oxford Green) - 2006 E86 M Coupe (Sepang Bronze)
    2001 E39 530i Sport (Aspen Silver) - 2009 E92 M3 (Space Grey)
    2001 E38 740i Sport (Sahara Beige) - 2008 E92 M3 (Melbourne Red)
    2000 E38 740i Sport Canadian (Sahara Beige) - 1997 E31 850Ci (Jet Black)

  11. #36
    Join Date
    Mar 2017
    Location
    Columbia, SC 29223
    Posts
    1
    My Cars
    2008 BMW 535XI wagon

    Same story!

    I have a 2008 BMW 535XI wagon. The light warning sign came on. I saw the left side DRL was out. Opened the cover and found out all insulation has dropped off! I live in Columbia, SC and the car is always garaged and well maintained!





    Quote Originally Posted by Budsbmw View Post
    Hi all,
    I had assumed that the headlight wiring issue was isolated to the E60's but a post on another forum has revealed a 2004 330Ci to be affected as well.

    I guess I should start to list known vehicles of people that have a wiring problem.
    Not that it means if you do not own one of the cars listed you are safe, I would still urge ALL BMW Car owners to keep a close look inside their headlights.
    However if you DO own one of the cars listed below you really need to be very aware of this problem and keep an eye on your headlight.
    It is a Cancer in your headlight and the earlier that you catch it, the easier it is to repair.

    Starting with my car first:


    1) 2006 530i (with Adaptive Headlights. Part # 63-12-7-160-157)
    2) 2004 525i
    3) 2004 530i
    4) 2004 545i
    5) 2004 330Ci
    6) 2007 530i
    7) 2007 335i
    8) 2008 528i
    9) 2008 535i
    10) 2008 550i


    If you have this problem and do not see your car listed please tell us here and I will update the list....

    Bud

  12. #37
    Join Date
    Jan 2011
    Location
    Oro Valley, AZ - USA
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    see my signature
    $1350 later, I finally have my '07 328i wagon sporting new (old stock) headlight housings, a used adaptive module from a 5 series, eBay ballasts and bulbs. Also had to get the modules re-coded so that the aiming motors would work. Pretty expensive endeavor that's all due to crappy design an even crappier components. I should update my thread soon with the new photos. Good luck with your 535xi!
    Last edited by Chamberlin; 03-21-2017 at 11:18 PM.
    2006 R53 JCW (British Racing Green) - 1994 E31 840Ci 6spd (AVUS Blue)
    2021 F56 JCW (Rebel Green) - 2000 E38 740i Sport (Titanium Silver)
    2017 F26 X4 M40i (Carbon Black) - 2007 E91 328iT (Deep Green)
    2012 E82 135i M Sport (Marrakesh Brown) - 2015 E84 X1 (Cashmere Silver)
    2005 E53 X5 3.0i Sport (Kalahari Beige) - 2000 E36/7 M Roadster (Oxford Green)
    2000 E38 740i Sport (Oxford Green) - 1999 E36 M3 Coupe (Fern Green)
    1995 E31 840Ci Canadian (Oxford Green) - 2000 E36/8 M Coupe (Oxford Green)
    2004 E46 330Ci (Oxford Green) - 2001 E36/8 Z3 3.0i Coupe (Oxford Green)
    2002 E39 525i Sport (Oxford Green) - 2002 E36/7 M Roadster (Oxford Green)
    2001 E53 X5 3.0i Sport (Oxford Green) - 2007 E63 M6 (Silver Grey)
    1995 E31 840Ci (Oxford Green) - 2006 E86 M Coupe (Sepang Bronze)
    2001 E39 530i Sport (Aspen Silver) - 2009 E92 M3 (Space Grey)
    2001 E38 740i Sport (Sahara Beige) - 2008 E92 M3 (Melbourne Red)
    2000 E38 740i Sport Canadian (Sahara Beige) - 1997 E31 850Ci (Jet Black)

  13. #38
    Join Date
    Oct 2011
    Location
    SoCal
    Posts
    292
    My Cars
    07' 530xi Touring
    This issue isn't with the Hella lights?

  14. #39
    Join Date
    May 2012
    Location
    Wesley Chapel
    Posts
    59
    My Cars
    2001 BMW 330Ci
    Quote Originally Posted by detins View Post
    Same situation here; bulbs have been replaced numerous times at dealership and at private Repair shops. No one mentioned insulation disintegration until the day light and high beam stopped working completely at same time. Quote for repair $2454.00. Ridiculous cost for something that should not have happened. Additionally, this is my only car that has the window trim that also disintegrated! Looking for a better option than spending $2500 for headlights on a 10 year old car valued at $4k! Anyone know someone in Orlando that can do this (besides a repair shop)?

    just replaced my h8 lights.. lots of errors with the bulbs shorting.. i put the electrical tape liquid all over and it helped but need to fix the adaptive headlight error... one thing after another with bmw.. major flaking.. im in florida...

  15. #40
    Join Date
    Apr 2017
    Location
    cape coral florida
    Posts
    1
    My Cars
    2010 528i
    Same exact problem, the wiring is flaking off. Headlights burn out every couple months on my 2010 528i.

  16. #41
    Join Date
    May 2012
    Location
    Wesley Chapel
    Posts
    59
    My Cars
    2001 BMW 330Ci
    Quote Originally Posted by bigaldakal View Post
    Same exact problem, the wiring is flaking off. Headlights burn out every couple months on my 2010 528i.
    I put a brand new headlight on now and found out what the damage is now.. FRM module needs to be replaced. Bought a brand new headlight as well. The FRM pulled a short circuit code which disables power to the headlight after 50 or so cycles.. after that you need someone who is a coder to clear it... super crappy imo this is turning into a fiasco due to Automotive Lighting making crap insulation jackets on these products.

  17. #42
    Join Date
    Nov 2016
    Location
    Texas
    Posts
    28
    My Cars
    01 330i, 05 545i project
    Have an 05 545i and have the same issue on both😠

    Sent from my SAMSUNG-SM-N920A using Tapatalk

  18. #43
    Join Date
    Mar 2010
    Location
    Abilene, TX
    Posts
    231
    My Cars
    1986 325e
    2004 545i same issue. I am afraid to even try to resolder new wires because the wite that look ok may start cracking.

    Sent from my SM-G900P using Tapatalk

  19. #44
    Join Date
    Dec 2010
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    Crestview,Florida Panhndl
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    E60 535i M-Sport
    So, since BMW won't "man up" on this issue what is the "solution"? I know that there are no good ones, but what have owners come up with, collectively?

    Solution if headlights are bad?

    Solution if headlights aren't bad, and one wants to help prolong the inevitable?

    (Thanks...I'm afraid to look at my or my son's cars)

    // Radar //
    2010 E60 535i N54 {sleeper}
    M-Sport, Alpine White w/Natural Brown Leather
    Coilovers, APEX Race Wheels
    Trebila-tuned motor, xHP Stage3 tranny tune,
    FBO+Meth FUN!!!

  20. #45
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    Mar 2010
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    Abilene, TX
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    1986 325e
    Quote Originally Posted by radarcontact View Post
    So, since BMW won't "man up" on this issue what is the "solution"? I know that there are no good ones, but what have owners come up with, collectively?

    Solution if headlights are bad?

    Solution if headlights aren't bad, and one wants to help prolong the inevitable?

    (Thanks...I'm afraid to look at my or my son's cars)

    // Radar //
    My solution was to cut the wires, slide on heat shrink tubing, then re-solder the wires. I tried to remove he wires out of the connectors, but even those were brittle. Only the wires I moved lost their shielding.

    Plan B was a headlight replacement at pelican parts. But I wanted to avoid dropping $600 if I could.

  21. #46
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    Atlantic Beach, Fl
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    81,e21 orig ownr&05,e60
    Buy a can of Liquid Electricians Tape and apply several coats to each wire separately. Time consuming but it works...

  22. #47
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    Quote Originally Posted by jtbgonesailing View Post
    Buy a can of Liquid Electricians Tape and apply several coats to each wire separately. Time consuming but it works...
    How well would this stuff hold to the heat temperatures? I chose the heat shrink tubing because it can withstand an open flame for a bit. Crossing my fingers on its longevity.

  23. #48
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    Quote Originally Posted by jbontke View Post
    How well would this stuff hold to the heat temperatures? I chose the heat shrink tubing because it can withstand an open flame for a bit. Crossing my fingers on its longevity.

    The Liquid Electritions Tape is some form of PVC that remains flexible after it cures and can handle the heat under the hood. I did my adaptive headlights 6-7 years ago and the product remains flexible with no signs of cracking or pealing. In fact I did all the wires, not just the ones where the insulation was deteriorating.

  24. #49
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    1986 325e
    Quote Originally Posted by jtbgonesailing View Post
    The Liquid Electritions Tape is some form of PVC that remains flexible after it cures and can handle the heat under the hood. I did my adaptive headlights 6-7 years ago and the product remains flexible with no signs of cracking or pealing. In fact I did all the wires, not just the ones where the insulation was deteriorating.
    That's great to know, if I get other cracks that are less accessible, this may be the solution.

  25. #50
    Join Date
    Nov 2011
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    Atlanta, GA
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    1995 530i - Dinan
    I have a 2006 X5 4.4i with the dynamic activeBi-Xenons and have the same flaking issue with the insulation. I decided toinvestigate when my drivers side low beam went out. Before I looked at thewires closely, I ended up swapping the bulb, igniter, and ballast betweenlights to trouble shoot the bad component. All worked fine in the otherheadlamp. It was only then that I looked at the wires closely. It was worst onthe 12v+ and ground wires for the actual bulb, ballast and igniter, but almostall of the wires had at least cracks in the insulation. Needless tosay, the LCM did it’s job, sensed the short and cut power to the lamp.




    I obviously had a short. I went the route of using heat shrink on all of the wires. I was lucky that the connector, terminals and copper conductors were in very good condition.







    Here are a couple of shots of the finished fix…





    I didn’t have to cut any wires or do any soldering, I was able to slide the heat shrink over the terminals without any issues.





    I bench tested the assembly, and the lamp works fine with a 12v transformer.



    So now I have the assembly back in the X5 and this is where my problem comes in. The LCM is still holding the short fault codes, and won’t power the light. I tried disconnecting the battery, letting it sit to clear any residual power in any of the modules overnight, and reconnecting the battery, but still no light on the driver side.
    How do you clear the fault codes in the LCM? Do I have to take it to a shop? Is there a hack fix, pulling a relay or fuse, or jumping a wire somewhere on the service port under the hood? Or do I need to find someone with a BMW code reader that can plug into my OBDII port and clear it that way?
    I’ve seen lots of stuff on swapping in a used module from another car and recoding it to the new vehicle, but I just need to reset the one I have. It appears to be doing its job well. Any and all advice welcome, my X5 is stuck in the garage with the bumper hanging half off of it until I can figure this out. Thanks!
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