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Thread: popup headlamp malfunction

  1. #1
    Join Date
    Jun 2009
    brooklyn, NY
    My Cars
    850i/audi s8/lambo lp560

    popup headlamp malfunction

    hello 8'ers. when i put my pop up headlamps on, only the left side popped up but the right side does not. the lights coming out of the headlamps work fine and come on with the headlight switch up but the right side won't pop back down after i flip the switch off. has anyone had this problem before or can tell me what they think could be going on. thanks

  2. #2
    Join Date
    Feb 2010
    Hampshire UK
    My Cars
    99 840ci Sport Indv
    The most likely candidate is K39 - the headlight relay:

    It contains a PCB with a small amount of electronics and the relays - the joints on the PCB fatigue after a while and can usually be successfully re-flowed. The fatigued joints are not immediately obvious, so get out the flux and soldering iron and all will be fine afterwards!
    Timm..2007 E64 650i Individual Sport..1999 E31 840ci Individual Sport..ex owner of 2000 E38 740..1999 E38 740i V8 M62..1998 E38 735i V8..1993 E32 730i V8..1988 E28 518i

    My Current 840ci Sport Individual
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  3. #3
    Join Date
    Jul 2014
    Westfield, IN
    My Cars
    '91 e31 M70 |'01 e38 M73
    Yes. It is typically the green headlight relays. The solder just get tiny micro cracks. Get someone to give you a hand and lightly press down on the pop up relay in the engine compartment relay box while they are operating the headlights. Sometimes you can get the solder joints to make contact to verify that's the issue.

    If you are a DIYer, there is a write up in this forum somewhere on how to reflow the solder to correct the issue. Not complicated, but a bit of a delicate operation. Why would someone go to those lengths to fix a cheap little relay instead of replacing it you say? Well, unfortunately, these headlight relays for our cars (3 in total) are around $175 EACH!

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  4. #4
    Join Date
    Dec 2009
    Gardendale, AL USA
    My Cars
    1995 840 Ci, 1959 Sprite
    Yep, at least $180 or so to buy new. It took all of 10 minutes to reflow the solder. I could not see any cracks or corrosion but reflowing immediately cured this problem. Try it!

  5. #5
    Join Date
    Jul 2007
    Cave Creek, AZ
    My Cars
    1993 850ci 2001 M5
    We have had great results re-flowing the solder as well on 3 cars here in AZ

    Cave Creek, AZ

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