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Headlight bulbs failure?

34K views 40 replies 27 participants last post by  MsNomer  
#1 ·
I have read a lot about the common headlight bulb failures. It seems weird that some guys report no failures and others are replacing bulbs every 10,000 miles. Has anyone figured out the root of this issue? I stopped in my local dealer today and he acknowledged that they have dealt with this issue but said they have no clue what causes it. He thought maybe possible a voltage surge. He told me Dodge/Fiat has a new superseded part # for a heavy duty bulb.
 
#2 ·
It is not common! I think most of them were ’14s and this may have worked itself out as FCA got on top of the van’s weaknesses I have a ’15 and know several others who do and none of our small circle have that problem. Lots of ‘14s don’t either. Those that have the problem have it for other bulbs too if my memory is correct, which it often isn’t. If they’re are ‘16s and on with bulb replacement issues perhaps they can post up here. We are still hearing from ’14 owners about 6 or so issues that just don’t seem to be happening to later vans but the chatter continues. It’s the nature of forums to blow an occasional fault into a major topic that just won’t stop which is why FCA should put real effort into those that have them.
I can see you are doing due diligence on the possible issues. It’ll scare ya. Nothing like a public forum to air your issue OVER and OVER! To give the posters their due it is a place to be heard, perhaps get help, and support. They often are dealing with a situation not of their making that may be ruining their vacations, stressing their family and killing their ability to do their work. It is important to them.
 
#13 ·
It is not common! I think most of them were ’14s and this may have worked itself out as FCA got on top of the van’s weaknesses I have a ’15 and know several others who do and none of our small circle have that problem. Lots of ‘14s don’t either. Those that have the problem have it for other bulbs too if my memory is correct, which it often isn’t. If they’re are ‘16s and on with bulb replacement issues perhaps they can post up here. W
We have a 2016. Headlight went out at 26,000 miles while vacationing. Tried to replace myself on the road, couldn't do it. Had to drive to a dealer to get it done (125 miles in NM). Charged about $55 for bulb and labor.

Had my home dealer in MN look for a technical bulletin on this and they claimed there wasn't one. Of course, this very same service provider (Fury Motors in Inver Grove Heights, MN) will also rotate my tires and not check the pressure, leaving the rear tires at 65lb and front at 80lbs, so I don't put much faith in anything they tell me...

It's possible that I don't have the problem, that this was a fluke bad bulb. Only time will tell. But a bulb should last more than 26,000 miles/14 months. And the engineers who designed the headlamp should be fired. It is absolutely stupid that the system should be so convoluted. No bulb should ever be harder than simple plug n' play. That's just dumb, dumb, dumb design.

Otherwise, we love our Promaster!
 
#11 ·
Are yours DRL’s? I wonder if the headlight out syndrome is in that light and system as mine would not be on if you saw me driving as I don’t have nor want DRL’s. I’m at 52,000 in three years with all origional bulbs but not DRL.
 
#14 ·
Daytime running lights are a separate bulb // circuit.

No bulb outs for my 2014 (yet) but they sure got much dimmer after 30 or 40 hours nighttime driving, still nice pattern but not the 'projector' effect they had compared to my old F-150...

Those $100 LED low-beam sets with 3 or 4 times the lumen output - I wonder how much additional long distance night driving fatigue they contribute...
 
#15 ·
My 14 PM is still on all of its original bulbs. But about once a week, the dash gives me messages on start up that my turn signals aren't working. I test them and they ARE working and then the computer shuts up about it. Maybe they're about to blow? I dunno yet.
 
#16 ·
We have 3 2017 pro masters , 1 of them don’t think we have changed the bulbs out 1 time yet. The other 2 we change the drivers side bulb out roughly every 3 months and never had an issue with the passenger side. We even tried LED bulbs in one of the pro masters thinking the separate voltage transformer would somehow help.... it didn’t .5 months later the drivers side is not completely out but flickering and doing weird stuff and half as bright as the passenger side . I see endless pro masters in the road with the drivers side bulb out. I see tho spots is kinda old just wondering of there is any updates on a actual solution .
Thank you
 
#19 ·
I went through severla bulbs on my 2016. I used to leave the lights on day and night. The first few years we spent a lot of time off road. Now using the long life bulbs, turn the lights off during the day, spend most of our time on road and have not replaced a bulb in over a year/25k miles
 
#20 ·
I am just under 80,000 mi. and approaching 5 years and I am on the origional bulbs in my ’15 diesel.
 
#25 ·
It is likely from high voltage. Your alternator is not regulating correctly. I am at nearly 5 years and 80K miles with all the origional lights, as it should be.
 
#34 ·
I guess one could try a series resistor as suggested in the writeup Phil provided.

For a typical 55 watt headlamp, current is about 55 watt/13 volt = 4.2 amps. A 0.2 ohm resistor in series with the lamp lead would drop the voltage by about (4.2 amp)(0.2 ohm) = 0.8 volts -- so, 14 volts would be taken down to 13.2 volts. Power rating would be about (4.2 amp)(0.8 volt) = 3.4 watts.

Something like this might work: uxcell 25W 0.2 Ohm 5% Aluminum Housing Resistor Screw Tap Chassis Mounted Aluminum Case Wirewound Resistor Load Resistors Gold Tone 2 pcs: Amazon.com: Electronics

I just replaced my headlamp bulbs at 80K miles -- not because they burned out, but because I thought they were about due and doing it on a sunny day in the driveway seemed better than in the middle of a blizzard out on the road :)

Gary
 
#29 ·
I know I posted a year and a half ago. But at 5 years old, my 14 model is still running all original bulbs except for the turn signals in the sides of the mirrors. Those got replaced under a service bulletin after one went out.
 
#35 ·
I have a '14 2500 PM and my drivers side headlight went out. When I took the bulb out to replace it I noticed the bulb was completely fine but the plastic connector that mounts the bulb melted out. Must have been getting way too much voltage. Anyone have this issue or know of the part to fix? I called the dealer but they said I would need to replace the entire headlight unit instead of one tiny part.
 
#38 ·
Hi @dcather1 - Should you have to work with your dealer for this concern, our team is just a private message away and we would be happy to provide you with an additional layer of support for that process. Please do not hesitate to reach out!

Mark
RamCares