new twist on ballast replacement

[diagnosticator]

For a bi-xenon conversion (halogen in my A4, bought bi-xenon housings) does anyone know where to get the additional parts necessary? I.e. Cable from ballast to bulb, screws, seal? Also, from my understanding, I need an extension cable for the passenger side?

EDIT: Really, I guess all I need to know is the thread type and pitch of the OEM screws, and where to get the cable to the bulb. I'm sure I can make a seal.

The screws are course threaded for unthreaded holes, the screws form the threads when tightened into the holes, and bite into the plastic of the housing. 6-32 screws will work as well IIRC. Optionally, use an 8-32 tap and cut 8-32 threads into the plastic holes, and use 8-32 X 1/2" long SS socket head cap screws. For a gasket, get a sheet of 1/8" thick rubber stock, and trace out the ballast outline and use a straight edge to draw the inside lines, then carefully cut out a pair of gaskets using a x-acto knife or similar. Guide the cuts using a straight edge with the cutting blade tight to the straight edge aligned on the traced outlines. For the screw holes, cut out small "v" or 1/2 circle U notches in the outside edges of the gasket placed to clear the screw holes.

[BCsniper]

interested in how these turn out? these OEM 4300K I assume?

The "random" seller on Amazon was great actually and shipped them very fast. I received them in about 5 days or so. Genuine Phillips 4300k just in different packaging.

I have the same question here I have the 4 port plug with a 12 port ballasts. How would I connect them? The 4 port plug will not go into any slot of the 12port connector. Any help out there I need to do this ASAP

Also I would assume the little 3 pin connector from ballasts to bulb is the same or all year Audis.

Any one know where I can get the connector from bulb to harness like within 1-2 days and would love to get info on how to make my 4 wire connector connect into the 12 pin socket. Thanks

I'd assume you could steal all of the pieces off your old lights and hack this together to make it work. Take the bulb to ballasts cables off you old lights and swap them to these. Use the 12-pin end from your old halogen lights and replace the 4-pin one on the Bi-Xenons with the 12-pin (All though you are aware that the Valea 5G ballasts will not fit into the back of the Bi-Xenon housing without cutting into the plastic on the back. You will need the 5GL ballasts, which uses the 4-pin).

The screws are course threaded for unthreaded holes, the screws form the threads when tightened into the holes, and bite into the plastic of the housing. 6-32 screws will work as well IIRC. Optionally, use an 8-32 tap and cut 8-32 threads into the plastic holes, and use 8-32 X 1/2" long SS socket head cap screws. For a gasket, get a sheet of 1/8" thick rubber stock, and trace out the ballast outline and use a straight edge to draw the inside lines, then carefully cut out a pair of gaskets using a x-acto knife or similar. Guide the cuts using a straight edge with the cutting blade tight to the straight edge aligned on the traced outlines. For the screw holes, cut out small "v" or 1/2 circle U notches in the outside edges of the gasket placed to clear the screw holes.

I'm pretty sure PNWAvant already got all sorted out (lucky bastard). I've been getting dicked around with different forum members trying to source parts and it's been a PITA. I'm still trying to get a god set of 5GL ballasts. I also CAN confirm that if you have an'03 you will need the harness extension for the passenger side. PNWAvant, did you end up needing one for yours?



oh and side note: the plastic on the back of Bi-Xenons housings is shit. I've seen pictures of other peoples housings which have cracks in them on the back where the ballast screws to the housing. I didn't think mine looked like that at all. Well when I went to install a set of ballasts I found out that mine too had some nice cracks in them. Apparently those screws were not meant to be tightened down super tight, and that the plastic on the back of the housing is pretty weak so if yours has not already cracked, then be careful

[DaSkorpion]

The "cable from ballast to bulb" can be found cheap on the bay check out listing #160566763693 or search for D1S cable ** took me a while but got all my parts together after some little research.

Enjoy

[PNW Avant]

The "random" seller on Amazon was great actually and shipped them very fast. I received them in about 5 days or so. Genuine Phillips 4300k just in different packaging.

I'm pretty sure PNWAvant already got all sorted out (lucky bastard). I've been getting dicked around with different forum members trying to source parts and it's been a PITA. I'm still trying to get a god set of 5GL ballasts. I also CAN confirm that if you have an'03 you will need the harness extension for the passenger side. PNWAvant, did you end up needing one for yours?

Yes, i got lucky and Jens (lowestA4) hooked me up with seals screws and bulb-ballast cables.

Yes, I needed an extension. From my research, it sounds like any halogen to xenon conversion will require the extension. However, single xenon to bi-xenon will not require an extension.

Here's some pictures of the extension I made:

Regular old butt-connectors. Pairs of 3 offset from each other.


Individually shink-wrapped


Shink-wrapped together


Finished product!


It works! Behold! Brand new ballasts, brand new OEM Phillips bulbs purchased from Amazon. Looks great!


Housings out of an 18k miles B6 S4 :)

[b7a]

Finished product!

Wow that looks clean! Nice work

[Scrwedtxboy31]

Yes, i got lucky and Jens (lowestA4) hooked me up with seals screws and bulb-ballast cables.

Yes, I needed an extension. From my research, it sounds like any halogen to xenon conversion will require the extension. However, single xenon to bi-xenon will not require an extension.

Here's some pictures of the extension I made:

Regular old butt-connectors. Pairs of 3 offset from each other.


Individually shink-wrapped


Shink-wrapped together


Finished product!


It works! Behold! Brand new ballasts, brand new OEM Phillips bulbs purchased from Amazon. Looks great!


Housings out of an 18k miles B6 S4 :)

Nicely done bro! Great work and as stated above that 4th pic is sick nasty!

[BCsniper]

However, single xenon to bi-xenon will not require an extension.

you can just go ahead and just shut the hell up on that part... (I got so mad finding out I couldn't plug my lights in)

I've got the A4 Xenon headlights in my '03 Avant and there was no way to get the harness to reach the Bi-Xenon Housing without an extension

Housings out of an 18k miles B6 S4 :)

Why does it look like the housing has a hole in the lens?

[jimbro]

Speaking of bi-xenons, does anyone know if you can buy the plastic piece of the housing that the ballast attaches to. I have a condensation problem and i noticed that its cracked where this attaches to the main housing.

[BCsniper]

I'm beginning to think that this is the cheapest option if you need all the pieces (including a set of D1S bulbs)

http://cgi.ebay.com/ebaymotors/OEM-V...Q5fAccessories
the price to buy here from ebay is $100 less than buying straight from the HID concept website

[PNW Avant]

I'm beginning to think that this is the cheapest option if you need all the pieces (including a set of D1S bulbs)

http://cgi.ebay.com/ebaymotors/OEM-V...Q5fAccessories
the price to buy here from ebay is $100 less than buying straight from the HID concept website

Good work - I like. But, they are used vs new ballasts.

Two new LAD5GL ballasts would be ~$240 right now plus shipping, from moparpartsamerica.com.

Whats the price for two new bulbs and two new cables? That's the question. If it's within ~$50 total price...I'd splurge for the new ballast.

[AvantinUSP]

Good work - I like. But, they are used vs new ballasts.

Two new LAD5GL ballasts would be ~$240 right now plus shipping, from moparpartsamerica.com.

Whats the price for two new bulbs and two new cables? That's the question. If it's within ~$50 total price...I'd splurge for the new ballast.

Just get some aftermarket bulbs i.e. ddmtuning, they're $50. and I would buy new ballasts from mopar..I've had several used ones go out.

[BCsniper]

ahhhh, good eye. I did not notice they were (USED) ballasts in the Ebay auction. Explains why it was $100 less.

I'd also spring for the newer ballasts. I remember somebody posting over in the B6/7 S4 section about where on Amazon.com to get a set of D1S bulbs for like $60, but I don't see it still available right now. From what I'm looking at, by the time you've bought a set of bulbs, you've probably spent nearly the price for the "kit" from ebay, but still lack the cable from the ballast to bulb, and the 6 screws on each side along with the rubber seal. Not to mention piecing all the things together from multiple sources would be a pain since you'd have to pay for shipping from 2 to 3 different places instead for just one.

[PNW Avant]

ahhhh, good eye. I did not notice they were (USED) ballasts in the Ebay auction. Explains why it was $100 less.

I'd also spring for the newer ballasts. I remember somebody posting over in the B6/7 S4 section about where on Amazon.com to get a set of D1S bulbs for like $60, but I don't see it still available right now. From what I'm looking at, by the time you've bought a set of bulbs, you've probably spent nearly the price for the "kit" from ebay, but still lack the cable from the ballast to bulb, and the 6 screws on each side along with the rubber seal. Not to mention piecing all the things together from multiple sources would be a pain since you'd have to pay for shipping from 2 to 3 different places instead for just one.

Got the cables, screws, and seals from a forum member for $60 shipped.
Add ballasts from Mopar for ~240 + Shipping
All that's left are bulbs, which hopefully I can get for around $100 or less.

[1.8Turbo4me!]

just swapped out my halogen for bi-xenon, but it looks like i need a harness extension for the right (passenger side). the left side works nicely though! perhaps i'll play with it again tomorrow since i was running out of light.

[PNW Avant]

just swapped out my halogen for bi-xenon, but it looks like i need a harness extension for the right (passenger side). the left side works nicely though! perhaps i'll play with it again tomorrow since i was running out of light.

What year is your car? trying to figure out if I need this too. Where are you going to buy it?

Do you get an auto leveling error code? I'm pretty sure I read that I shouldn't - just want to make sure though.

[1.8Turbo4me!]

What year is your car? trying to figure out if I need this too. Where are you going to buy it?

Do you get an auto leveling error code? I'm pretty sure I read that I shouldn't - just want to make sure though.

Mine is a '03. Didn't find any online so I figured I make my own. Searching for the part numbers, I found Manguyen's old DIY: bi-xenon harness extension thread: http://www.audizine.com/forum/showth...ness-extension

Though only one harness and wire were in stock at my nearest audi dealer, I used my old halogen harness/housing and wire and just connected them together. It turned out exactly the way Manguyen's harness (pictured) looked but with electrical tape and heat shrink.


I then use more electrical tape to wire them together. (my harness)


as for the auto leveling error, i didn't get that since i didn't have that on my old halogen.

[PNW Avant]

Mine is a '03. Didn't find any online so I figured I make my own. Searching for the part numbers, I found Manguyen's old DIY: bi-xenon harness extension thread: http://www.audizine.com/forum/showth...ness-extension

Though only one harness and wire were in stock at my nearest audi dealer, I used my old halogen harness/housing and wire and just connected them together. It turned out exactly the way his looked but with electrical tape and heat shrink.

From the DIY:
Female Harness: 1J0 973 735
Male Harness: 1J0 973 835

Wiring for female end: 000 979 133 (A) (the A is for gold plated)
Wiring for male end, with pins: 000 797 134 (A)

I can find both harnesses on genuine audi parts.com, but I can only find the top set of wires. The other set is not listed as a valid part number.

When you reused the harness from your halogen, I assume you had to cut it out then?

[AvantinUSP]

PNW Avant, have you actually tried fitting them in? I have an 04 and I didn't need an extension, though mine came with stock xenons.

[1.8Turbo4me!]

From the DIY:
Female Harness: 1J0 973 735
Male Harness: 1J0 973 835

Wiring for female end: 000 979 133 (A) (the A is for gold plated)
Wiring for male end, with pins: 000 797 134 (A)

I can find both harnesses on genuine audi parts.com, but I can only find the top set of wires. The other set is not listed as a valid part number.

When you reused the harness from your halogen, I assume you had to cut it out then?

yeah, forgot to mention. the wiring for the male end is actually 000-979-134-A. i think Manguyen flipped flopped the middle numbers by mistake. the parts fella corrected me as well.

but i did cut my wires from the halogen.

[PNW Avant]

Mopar Parts America FTW!







Part number 5139061AA
$120+ $19 shipping per ballast

[cneedelman]

got the Valeo LAD5G for my 03 A4 from oemxenonpart <[email protected]> out of China, $215 deliverd in 5 days great price! Just wanted to post this so others don't have to go thru what i did until I bit the bullet and decided to order from China. Mopar may have had the equivalent to the LADG, but i didn't want to take a chance that it was the wrong part. I sent a picture to oemxenon and he confirmed that he had the Valeo with the 12 pin cable.

[Scrwedtxboy31]

Wanted to post this up for everyone. Help IDENTIFYING YOUR HEADLIGHT/BALLAST-****> clicky click

*Special thank you to Ilko for posting this in his for sale post as this is great info!

[boostedAvant]

Chrysler dealer wants 175$ Looks like I'll be ordering mine off moparparts.

[Scrwedtxboy31]

Chrysler dealer wants 175$ Looks like I'll be ordering mine off moparparts.

yea man its a great deal, as soon as I found this out it was on like donkey kong! The only have the LAD5GL though as far as I know (4 pin)

[Scrwedtxboy31]

Chrysler dealer wants 175$ Looks like I'll be ordering mine off moparparts.

yea man its a great deal, as soon as I found this out it was on like donkey kong! The only have the LAD5GL though as far as I know (4 pin)

[boostedAvant]

That's what I have so we're all good there. Now I just need a pay check! So tired of having this headlight out. It's been going on for wayyyy too long.

[eurojetta]

Where do you guys recommend getting bulbs? Is the $239ea on ChryslerPartsDirect.com a good price?

[BCsniper]

bought a set of Phillips D1S a couple days ago of Amazon, either $47 or $54/each depending on what seller you're going for. I'm taking a gamble and going with the cheaper (random seller)

http://www.amazon.com/Philips-Xenon-...2136232&sr=8-1

[Scrwedtxboy31]

bought a set of Phillips D1S a couple days ago of Amazon, either $47 or $54/each depending on what seller you're going for. I'm taking a gamble and going with the cheaper (random seller)

http://www.amazon.com/Philips-Xenon-...2136232&sr=8-1

interested in how these turn out? these OEM 4300K I assume?

[boostedAvant]

I got my bulbs off DDM for 50$ for the pair. A lot of people on here hate DDM but they've lasted me a while so far.

[1BAD4DR]

Bump come on Ziners help me out^^^^^

[BCsniper]

I'd take a guess as that that's where that '04+ on thing comes into play. Maybe if yo have an '03 or earlier Single Xenon then you will need an extension, but if you're '04+ then you wont, and it you never had Xenons in the first place then you will for sure.


Now.........If you have the Bi-Xenon S4's, PNWAvant, why have you yet to take the amber out of the housing. NO AMBERLAMPS!!!

that was one of the first things I did when I got mine and I have still yet to be able to put them in and have them working

[PNW Avant]

I'd take a guess as that that's where that '04+ on thing comes into play. Maybe if yo have an '03 or earlier Single Xenon then you will need an extension, but if you're '04+ then you wont, and it you never had Xenons in the first place then you will for sure.


Now.........If you have the Bi-Xenon S4's, PNWAvant, why have you yet to take the amber out of the housing. NO AMBERLAMPS!!!

that was one of the first things I did when I got mine and I have still yet to be able to put them in and have them working

Haha, I thought about it! But they were in such perfect condition that I didn't want to break the corners out . I'm really after Bi-xenon e-codes, so I want to be able to sell these as perfect bi-xenon housings down the road when the time comes.

[BCsniper]

Looks Great Man!

Haha, I thought about it! But they were in such perfect condition that I didn't want to break the corners out . I'm really after Bi-xenon e-codes, so I want to be able to sell these as perfect bi-xenon housings down the road when the time comes.

it's really not too hard, and I can imagine they'd only get you a couple more bucks if they were CC'd, unless maybe if somebody from Europe wanted them and preferred the amber

[PNW Avant]

Got the final aiming done, according to this helpful write-up. http://www.danielsternlighting.com/tech/aim/aim.html





All done!

[the sheriff]

I can't be the only one that can't get these harnesses to click in to one another....the simply don't seem to want to go.

[BCsniper]

You talking about the harness for the extension needed for the pass. side when doing an S4 Bi-Xenon swap?

Or are you referring to the harness that plugs into the ballast?

Whichever it is they should just click right together. Do you have them turned the wrong way possibly?

[the sheriff]

You talking about the harness for the extension needed for the pass. side when doing an S4 Bi-Xenon swap?

Or are you referring to the harness that plugs into the ballast?

Whichever it is they should just click right together. Do you have them turned the wrong way possibly?

i'm talking about constructing the extension for the harness.....plug n' play is certainly not happening. all the correct part numbers are had, double checked.....

[BCsniper]

can you take pics of the pieces you're having trouble with.

I just got my Bi-Xenons in about a week or 2 ago and also had to make an extension just like pretty much everyone else. My steps were pretty much the exact same as original write-up and the summary PNW Avant did only thing different for mine was I needed 10 wires, not 6 since I had A4 Xenons before so I had the wiring for things like auto-level. The connectors on the wiring harness should make the same "click" that it does when normally plugging in your lights, altho I'm sure you know all of this so I'm not exactly sure where your trouble is. If you could take a pic maybe we'd be of more help

[the sheriff]

can you take pics of the pieces you're having trouble with.

I just got my Bi-Xenons in about a week or 2 ago and also had to make an extension just like pretty much everyone else. My steps were pretty much the exact same as original write-up and the summary PNW Avant did only thing different for mine was I needed 10 wires, not 6 since I had A4 Xenons before so I had the wiring for things like auto-level. The connectors on the wiring harness should make the same "click" that it does when normally plugging in your lights, altho I'm sure you know all of this so I'm not exactly sure where your trouble is. If you could take a pic maybe we'd be of more help

I'll try and get you some pics tonight....this is kind of baffling...