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Halogen headlights: Recall fix on harness vs LED's

Discussion in 'Lighting' started by Tundra234, Jul 5, 2022.

  1. Jul 5, 2022 at 9:14 AM
    #1
    Tundra234

    Tundra234 [OP] New Member

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    @RainMan_PNW, @Jeff_5_7, @iHacker

    Question for you guys since this seems to be popping up in a few threads. I'm not sure how in depth you guys are following the halogen recall issue, but questions are popping up about the harness "modification" and LEDs. Many have upgraded to led headlights whether they are OEM's with ihackers harness or Morimoto XB's. The common question seems to be "Is the led upgrade still potentially affected by the harness issue if the recall is not performed?" The 2nd question being asked is "Should I get the recall procedure done even though they switched to leds? "

    As far as for repairs to the harness, some guys have said that a section was cut and spliced in and looks like a hackjob. Another member said that relays were added to his. I would like to see what the repair guidance given to the dealers looks like, but they are not replacing the entire harness. IMO, splicing (if not done correctly) seems like a way of leading to corrosion issues in the wiring. Thanks for any inputs that you guys have. Attached is a document that I found discussing the issues with the harness.
     

    Attached Files:

  2. Jul 5, 2022 at 9:29 AM
    #2
    RainMan_PNW

    RainMan_PNW SSEM #82 RGBA #4 “That Guy”

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    TBH, I haven’t followed it. The only “recall” I was aware of was regarding the DRL/blinker where they had the terminals in that bulb socket switched for “high” and “low”. The fix for that is a pretty easy determ/reterm of the connector that shouldn’t require any relays or cut/splice.

    And I haven’t really followed the ihacker harness either because I already had LED headlights in my truck when I bought it.
     
  3. Jul 5, 2022 at 9:43 AM
    #3
    Tundra234

    Tundra234 [OP] New Member

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    Gotcha. We just know how you guys like relays and stuff. :D Some of us aren't feeling too confident in the dealers repairs, and they don't seem to be consistent. I have the Morimotos in mine and I wont let them touch it if it isnt necessary.
     
  4. Jul 5, 2022 at 1:47 PM
    #4
    Jeff_5_7

    Jeff_5_7 New Member

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    "If the high beams are subjected to repeated extended use (e.g., continuously switched “on” in a commercial setting when the vehicle is idling or driving at low speed for extended periods of time and not allowing air flow to cool the headlamp connector), excess heat over multiple days could lead to degradation of the bulb insulation and eventually the bulb connector"

    So basically the fleet / oil field guys are leaving the trucks parked running with the high beams on (as well as low beams due to the wiring issue) for hours, if not days at a time. The document mentions Midland, and those guys out there do crazy stuff with fleet work trucks owned by companies. I have heard stories of lease trucks running/idling for over a week at a time ect. Workers on different shifts sharing trucks.

    The heat from the incandescent bulb is making it melt itself after days of high beam use while parked with no driving airflow to help cool it. Toyota said they tried to replicate it and on the 31st day of 8 hours of highbeams and lowbeams it finally caught on fire.

    Odd yet interesting problem to have. Seems you only get into trouble if you have high and low beams on and leave the truck parked stationary for more than 30 mins. The bulb gets very hot and repeating the process it just gets worse and worse over the days. I personally don't use my highbeams that much and definitely never just parked the truck with them on for an extended period of time. I only use them on nighttime highway trips out of town it seems.

    I think its more of a heat issue than it is a harness issues. LEDs should consume less power and run at lower temperatures than the halogen bulbs. I know the guys up north were mad that the LEDs dont get hot enough to melt the ice off the headlights in the winter. Regardless if I had the LEDS I wouldn't be worried, even if I had the halogens I wouldn't be that concerned. Evidence shows its really only a problem under extreme abuse conditions. Toyota had to leave the headlight stationary (no cooling) running 8 hours a day high and low beam and it still took a full month to get bad enough to actually catch on fire.

    I assume they are cutting up the harness and adding relays to make sure only the high beam or only the low beam are on and never a scenario where both come on at the same time. This drastically cuts down power consumption and heat generation. This is a heat problem from extended usage being labeled as a wiring problem because the wiring is allowing both high/low to operate simultaneously.
     
  5. Jul 5, 2022 at 1:53 PM
    #5
    Tundra234

    Tundra234 [OP] New Member

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    Makes sense to me with the heat issue. On a side note, I thought that on most vehicles the low beams turned off when the high beams come on unless you have leds.
     
  6. Jul 5, 2022 at 1:54 PM
    #6
    FitsofRage88

    FitsofRage88 real eyes realize real lies.

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    Will mention iHacker harness addresses the DRL/blinker where they had the terminals in that bulb socket switched for “high” and “low”. In other words you already know when you do order the iHacker harnesses that that is one item fixed that you get with the purchase…
     
  7. Jul 5, 2022 at 2:08 PM
    #7
    Jeff_5_7

    Jeff_5_7 New Member

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    I had assumed all 2018 and up trucks were LED honestly hahah. Anyway seems some are definitely halogen. I have hunch Toyota designed a new LED harness that keep low beams on when high comes on. Then they accidentally just used this same setup for all trucks LED and halogen. Now they are calling it a design flaw because the good old boys in the oilfield abused the shit out of it and made it catch on fire.

    It happened enough that Toyota was "aware" of the issue. The recall is a cover your ass, if they didn't do it and then someone died or garage burned down in the middle of the night Toyota would be had for knowing about the "problem" and then pretending it wasn't that big of a deal, which it really isn't.
     
  8. Jul 5, 2022 at 5:21 PM
    #8
    RainMan_PNW

    RainMan_PNW SSEM #82 RGBA #4 “That Guy”

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    The lows stayed on with the highs on my 2008 as well - never had an issue. I thought that was pretty common. It’s the fogs that shut off if the highs are on so that no more than two forward lights are on (per DOT requirements)
     
  9. Jul 5, 2022 at 5:25 PM
    #9
    MadMaxCanon

    MadMaxCanon New Member

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    Too many, but not enough....
    Mayne someone with the led conversion could leave the hi beams on a while and feel if its getting hot enough to melt wire? That would have to be pretty damn hot
     
  10. Jul 5, 2022 at 5:34 PM
    #10
    Tundra234

    Tundra234 [OP] New Member

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    The SR, SX, and SR5's are halogens. Yeah who knows what's actually the issue with the harness. I'd still love to see what the written guidance is for the dealers to use for the repair.
     
  11. Jul 5, 2022 at 5:46 PM
    #11
    RainMan_PNW

    RainMan_PNW SSEM #82 RGBA #4 “That Guy”

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    That should be in a written TSB - which should be available on TIS
     
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  12. Jul 5, 2022 at 5:51 PM
    #12
    Jeff_5_7

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    Who wants to pay $20 to download it?

    I assume Toyota is just trying to decrease the load and heat generated by the headlight to keep it from degrading.
     
  13. Jul 7, 2022 at 6:26 PM
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    Jeff_5_7

    Jeff_5_7 New Member

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    Was in the TIS so I grabbed these. Haven't read them yet but its the recall letter, repair instructions ect.
     

    Attached Files:

  14. Jul 7, 2022 at 6:51 PM
    #14
    RainMan_PNW

    RainMan_PNW SSEM #82 RGBA #4 “That Guy”

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    Per the first attachment, cut and splicing in a relay on each side.
     
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  15. Jul 8, 2022 at 7:25 PM
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    xJuice

    xJuice This guy...

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    Exactly what I have been looking for. Thanks brother!
     
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  16. Aug 8, 2022 at 5:39 AM
    #16
    MeetJoe

    MeetJoe New Member

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    I had halogens in my 21 crew max but ultimately upgraded to TRd Pro black LEDs with a ihacker harness.

    Dealer says they have a remedy for the recall and can apply it without impacting the aftermarket harness. Should I do it? Or decline the recall remedy since it’s aftermarket and shouldn’t matter since there are no more Hi-Lo halogens that could over heat.

    what should I do? I like having a clean truck with service and recalls addressed…

    do it? Don’t do it? Doesn’t matter? Thanks!
     
  17. Aug 8, 2022 at 6:03 AM
    #17
    Tundra234

    Tundra234 [OP] New Member

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    Look at the repair procedure and see if you want them to do it or not.
     
  18. Aug 8, 2022 at 1:50 PM
    #18
    RainMan_PNW

    RainMan_PNW SSEM #82 RGBA #4 “That Guy”

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    What George said

    I’m personally not a fan of the repair procedure they came up with, but it is officially released so that does mean if there are issues down the road from it, the factory has to cover it.

    The only issue you might have with NOT doing it is if you go to sell the truck, the vehicle history will show an open recall. No big deal otherwise.
     
  19. Aug 10, 2022 at 3:10 PM
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    Jtundra81

    Jtundra81 Just a member

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    What did you end up doing? I am scheduled for an appointment in couple weeks , I got reimbursed by Toyota for the led and iharness , I was planning to ask dealer to skip the procedure since no longer have halogen …
     
  20. Aug 11, 2022 at 12:49 PM
    #20
    MeetJoe

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    How did you get them to reimburse for LEDs and iHarness???

    leaning towards skipping the procedure too. They sent me the same files (attached in a previous post). Looks too invasive for an obsolete problem.
     
  21. Aug 11, 2022 at 12:53 PM
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    Tundra234

    Tundra234 [OP] New Member

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    It's a waste of time at this point.
     
  22. Aug 14, 2022 at 6:22 PM
    #22
    MeetJoe

    MeetJoe New Member

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    What are you saying is a waste of time:
    -the reimbursement?
    - the recall repair?
    - or both?

    the repair looks invasive and I don’t think it’s worth it since I don’t have the Halogen Hot Bulbs.
     
  23. Aug 14, 2022 at 6:24 PM
    #23
    Tundra234

    Tundra234 [OP] New Member

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    The reimbursement. I have called them 3 times in 2 weeks and they said that an email was sent to the claims department and that they will call me with a response. I have yet to receive that call.
     

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