Daytime Running Lights Melting Housing After Recall Replacement

So my DRL are melting the headlight housings again, just as they did before I had them replaced under the recall / TSB. Is this still active? I can't seem to find if they are still replacing housings.

Been approximately 1.5 years or so since I had them replaced.

Any insight would be appreciated

Mike

 

Subd for outcome.. had mine replaced about a yr ago as well. Hope this doesnt start happening again

 

Active or not take it to the dealer who replaced them and ask why it happened. Sounds like they didn't give you the right lights.. New lenses are supposed to be glass if I remember right.

 

[OP] can you post photos of your headlamps--the upgraded ones are readily identifiable.

The originals look like this--note the plastic DRL sub-assembly, and the prismatic diffuser moulded into the lens (below the burned spot):



This is a replacement housing--the sub-assembly is made of glass, the prismatic diffuser was eliminated:

 

I'll be damned, those reckless morons at the dealership bamboozled me. Thank you for the information, grabbing the pitchfork and torch tomorrow.

 

Yup looks liken they installed a new set--of the defective headlamps; damned idiots. Shit like this is why Toyota is losing it's edge.

Here are the part numbers for the upgraded housings:



See if you can get them to order the "sport" housings--they have a dark gray surround that makes them a bit distinctive:

 

Ruh Roh!

 

100% on the service parts department, they probably already had to eat the cost of the lights installed as Toyota would debit the claim.

Send me your vin and I'll check your service history in my system will have the parts numbers listed from the repair order

 

Please do this would be great intel; however I'll wager the repair order will show the part numbers for the upgraded housings--where they are now is a whole different story:

To be nice, it could be that through just plain incompetence they installed a "new" set of obsolete housings they had "on-the-shelf";

Or, it could be deliberate malfeasance in which they ordered the upgraded housings but installed installed the obsolete housings--the repair order indicated the upgrade housings were installed and the obsolete housings were removed from parts inventory, replaced by the new ones;

Or, they took the obsolete housings off a new or slightly used truck on the lot, installed them on the customer's truck and put the new ones on the vehicle in inventory--perhaps a "technician" took them from his own truck so he could get the new ones;

Or any number of possible scenarios in which the customer got a new/newish set of obsolete housings and the new housings went somewhere else...

 

That's a super informative post! Hopefully OP can get this resolved.

 

goodluck man! they almost did the same thing to mine until I started asking what was different about the new headlights, and then all of a sudden the cost to replace increased because they weren't going to put the new style on there. gotta stay on your toes man!

 

So after getting the run around from the service concierge, I finally got ahold of the service manager who asked for photos of the housings, VIN and odometer. I got the impression he wanted to make things right, so I'll give him a day or two as requested and see where it gets me.

As to the poster who offered to check out the service history, give me a moment and I'll PM you the VIN - I seriously appreciate the help.

Thanks all,

Mike

 

Sounds like some sort of progress, please let us know how it goes and how any of us (my presumptuously speaking for us all) might be of assistance...

 

Part Qty: 1 Part #: 8111004163 Part Desc: HEADLAMP ASSY, RH
Part Qty: 1 Part #: 8115004163 Part Desc: HEADLAMP ASSY, LH

So they did install the incorrect part on the truck.

 

So per Ty, they actually documented replacing my headlight assemblies with new, still defective assemblies. Should help my case if they try and give me the runaround.

Part Qty: 1 Part #: 8111004163 Part Desc: HEADLAMP ASSY, RH
Part Qty: 1 Part #: 8115004163Part Desc: HEADLAMP ASSY, LH

Thanks again Ty, appreciate ya checking into that.

 

It does a lot more than "help" your case, pretty much seals it.

The next question is was this incompetence or deliberate? Based on my experience with dealers it could go either way...

Here is the last revision of the TSB (PDF, 230kB), it includes a table showing both the old and new part numbers for the housings:



Happy hunting!

 

New headlights ordered and scheduled to be installed this Friday - thanks to everyone for all the help with this.

-Mike

 

As my son used to say (he's 48 now) "way cool!"...

 

Did you get the new headlights?

 

had this happen to me as well (new housings that were replaced under the service campaign started to melt). Invoice from the orig. replacement showed the "old" part #'s. I called Toyota Corp. to report it, explained it was one of two things.
1. the dealer originally replaced my housings with new but old model housings
OR
2. the "updated housings" per the TSB are just as defective as what was originally installed if they actually installed those.

They would not honor them paying a dealer directly to have them replaced but rather said if I went to a dealer, got a quote for replacement and sent it to them, they would look into options.
A few days later they contacted me back with "go to the authorized dealer of your choice, you pay for the replacement, send us a copy of the invoice and we'll send you a check for reimbursement, up to a certain dollar amount, which was much less than I actually had to spend.
Worked for me and I made sure when the housings came in I looked at them, the boxes had not been opened yet and all the part # labels on the outside of the box were the newer part numbers. I don't recall if the part number was stamped into the back side of the housing anywhere.
Lastly, I kick myself as I should have had the dealer order the "sport" headlight because at that point corp. would not have cared if it technically was not the part number for my truck, they were just looking for the amount to reimburse me for.