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09+ Melting DTRL Lens Recall Petition **URGENT**

Discussion in 'Lighting' started by ProForce, Oct 12, 2012.

  1. Oct 12, 2012 at 4:54 PM
    #1
    ProForce

    ProForce [OP] Thin Blue Line

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    Anthony
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    Too many to list. See build page. Link in signature
    UPDATE:For those of you in this thread having headlight problems, there is now GREAT news!

    Toyota has begun sending "Warranty Enhancement" letters out for 05+ Tacoma's with DRLs that will now cover the replacement of your headlights regardless of mileage if they are melting or discolored. This is NOT a safety recall, but simply a free extended warranty on that part only. No need to wait for the letter, go see your dealer for your free headlights!

    Check this thread for a copy of the letter and updated TSB info:

    http://www.tacomaworld.com/forum/2nd-gen-tacomas/336066-toyota-recall-melting-dtrls.html


    *************************************


    Hello TW,

    **(EDIT: I RECENTLY DETERMINED THIS ISSUE IS RELATED TO ALL 2005-2011 MODEL YEARS EQUIPPED WITH FACTORY DRL's, NOT JUST 2009-2011)**

    As most of us already know, 2nd Gen 2009-2011 model Tacoma's equipped with factory DTRL's are notorious for their melting lenses. From my research, this failure seems to be caused by a higher wattage bulb that Toyota began installing in 09+ models after multiple complaints of premature bulb failure in previous model years. This higher wattage bulb emits much higher amounts of heat, and Toyota failed to do proper R&D and testing to ensure our headlight lenses can compensate for this increased heat.

    As many of us have already fallen victim to this, some of us, like myself, have not experienced this failure until after being out of their original 3/36 warranty. Some owners report their dealerships denying claims, and having no success with help from Toyota HQ. Others have reported their dealerships taking the matter so serious, that a rental car was issued because the truck was deemed unsafe to drive. This seems to be a hit and miss situation.

    I brought my truck in to my dealership today (John Elway's Crown Toyota, Ontario CA) and had a service advisor write up my melted DTRL issue. I currently have 44k on the truck so I am no longer in factory 3/36 warranty, however I do have Toyota Extra Care Platinum 7/100 warranty with no deductible. My dealer informed me that the lens failure will not be covered, and that my Extra Care denied the claim.

    I immediately called Toyota HQ (1-800-331-4331) and opened a case number as advised to do by my service advisor. Toyota forwarded my claim back to the Customer Relations Manager and Service Director at my dealer. Dealer again denied the warranty work, and advised that Toyota HQ also denied my out-of-warranty claim. Called Toyota HQ back to push the issue further up the chain, but was denied access to speak with a manager/supervisor and was told I will be called back on Monday from my original claim writer. It is now a waiting game.

    With all this going on, I know I am not alone, and this is far from an isolated incident. If you visit NHTSA.gov or Safecar.gov, you will find hundreds of consumer complaints regarding this matter. Here on TW alone I am sure we can find several hundred members with this issue. This has gone on way too far.

    My main point of concern is that this is not a simple part failure like a door sill that causes wind noise, or a window switch that sticks, this is an extreme fire hazard and risk to not only us owners, but our passengers and others on the road. Vehicle fires kill people. I am a highly experienced and knowledgeable in 12v electrical, and although it may not seem like a bubbling piece of plastic will do harm, don't be fooled. Our lives are in danger, and its going to take a vehicle fire or death for Toyota to finally recognize this hazard.

    I was estimated $311 for a single replacement headlight assembly (with the same stock bulbs that caused original failure) plus $218 in labor. That is $540 for a single headlight replacement, without even addressing the original issue/failure. Although it is likely that I will eventually be "reimbursed" by Toyota HQ for PARTS ONLY, that is still not acceptable. It is time for us to take a stand against this and make our trucks safe again.

    I would like to begin by asking ALL of you that have experienced this problem before, please share your story and the results. Whether you decided to leave it as is, or if you took it to your dealer, please share what the outcome was. Were you in/out of warranty, what was the dealers advice, did you have extended warranty, did you contact Toyota HQ, were you reimbursed, who covered/denied coverage, do you have stock or aftermarket bulbs, etc.

    I realize their are many other threads on this topic already, so if you have already shared your story before, please share again. I have no intentions of backing down, and I need your support to make any significant results from this. If it takes a lawsuit, so be it. I will gladly hire an attorney and make something come of this. I am in the process of compiling existing consumer complaints, as well as existing threads on this topic, but the more I have the betted for my case.

    I am asking this community to please get together on this and share your story!! It is imperative I get as many personal stories as possible. Do not lie however, share only the facts!

    Thank you TW for your support on this matter!

    - Anthony (ProForce)
     
    Last edited: Jul 22, 2014
  2. Oct 12, 2012 at 4:54 PM
    #2
    ProForce

    ProForce [OP] Thin Blue Line

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    Online Resources Compilation:

    TOYOTA T-SB-0129-11 'Headlamp Assembly Appearance Concern' (see attached)

    Safercar.gov search results for 2009 Toyota Tacoma ONLY. Complaint numbers for burnt DTRL related issue only. First report on 5/5/11 and most recent on 10/11/12:
    10479782
    10478521
    10474315
    10473096
    10472857
    10470854
    10469976
    10469518
    10468007
    10465614
    10464632
    10460792
    10460424
    10459898
    10458786
    10456591
    10455374
    10452762
    10450706
    10435526
    10432814
    10424219
    10422660
    10421396
    10394260

    No reports on safecar.gov for any 2010-2011 models at this time, although Toyota has already officially confirmed part failure in these model years with the attached TSB.

    Safercar.gov complaint list from 2008 in regards to Burnt signal lenses ONLY:
    10457435
    10448124
    10427052
    10405463

    List for model years 2005-2007 pending



    RELATED TW THREADS:

    http://www.tacomaworld.com/forum/2nd-gen-tacomas/57290-drl-burnt-through-lens.html **SEE PICS!**
    http://www.tacomaworld.com/forum/2n...se-who-have-dtrl-its-melting-your-lights.html
    http://www.tacomaworld.com/forum/lighting/119333-anybody-else-have-headlight-lens-melt.html
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/181761-attn-09-11-12-headlight-lense-will-melt.html
    http://www.tacomaworld.com/forum/2n...refused-all-responsibility-melting-dtrls.html
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/162652-drl-melting-lenses.html
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/206029-headlamp-tsb.html
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/181997-dtrl-melting-lens.html
    http://www.tacomaworld.com/forum/2n...em-w-parkn-lights-melting-internal-lense.html
    http://www.tacomaworld.com/forum/lighting/139579-parking-light-plastic-melted.html
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/80533-dtrl-lens-melting.html
    http://www.tacomaworld.com/forum/2n...e-drls-have-they-damaged-your-headlights.html
    http://www.tacomaworld.com/forum/lighting/22417-daytime-running-light-issue.html
    http://www.tacomaworld.com/forum/lighting/43969-daytime-amber-lens-melted.html
    http://www.tacomaworld.com/forum/2nd-gen-tacomas/43277-drl-heads-up.html
    .... The list goes on and on and on!!!

    http://www.fmcsa.dot.gov/rules-regulations/administration/fmcsr/fmcsrruletext.aspx?reg=r49CFR571.108
    DOT rules (as found in above link) Standard 108 - Lamps, Reflective Devices, and Associated Equipment. See section 571.108 S5.1.2 A-G

    SAE Regulations concerning lens testing - Standard J576 JUL 91
    According to SAE standards (from what I interpreted) these lenses must be tested at approximately 170° F for 3 hours in a circulating oven... That means if these went through proper testing, then our bulbs are getting hotter than 170° F in under a 3 hour time frame in order to melt the lenses :eek:

    To be continued...
     

    Attached Files:

  3. Oct 12, 2012 at 7:25 PM
    #3
    TheSmash133

    TheSmash133 Cruise

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    I havn't experienced this personally, and I have an 06. Never had a problem and I just recently had the retrofit mod done! Good luck though bro!
     
  4. Oct 12, 2012 at 7:28 PM
    #4
    ProForce

    ProForce [OP] Thin Blue Line

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    This applies to 2009-2011 model years only.
     
  5. Oct 12, 2012 at 7:34 PM
    #5
    Ahshiet

    Ahshiet Well-Known Member

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    I change my bulbs pretty early on so didn't get the melt down but my cousin has a prerunner and got it about same time as me and his is melted beyond and a friend had a set that was sprayed aka smoked and started to melt and told the dealership that they going be reliable if it catches fire and that was the turning point and had them swapped for the glass ones
     
  6. Oct 12, 2012 at 9:18 PM
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    TXPRO4X4

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    Danm to much ro read right now
     
  7. Oct 12, 2012 at 9:37 PM
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    OffroadToy

    OffroadToy The dog did it...I swear!

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    Why not just change the bulbs? :confused:
     
  8. Oct 12, 2012 at 9:42 PM
    #8
    09DBLCAB09

    09DBLCAB09 Well-Known Member

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    Changing the bulb out isn't going to unmelt my headlight

    Mine is the same. I have a 09. Been going back and forth with Toyota dealership. They basically laugh at me and tell me they won't do anything about it
     
  9. Oct 12, 2012 at 9:43 PM
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    OZ-T

    OZ-T All of those moments....will be lost.....in time

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    Time to change the bulbs and live with it
     
  10. Oct 12, 2012 at 9:52 PM
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    OffroadToy

    OffroadToy The dog did it...I swear!

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    But it might save your life according to the op.
     
  11. Oct 12, 2012 at 10:48 PM
    #11
    09DBLCAB09

    09DBLCAB09 Well-Known Member

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    I highly doubt a little 3156 bulb that is slowly melting my headlight housing will somehow kill me
     
  12. Oct 12, 2012 at 10:55 PM
    #12
    krimson

    krimson Nothin

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    Way too much to read lol.. I just replaced mine after they showed signs of melting. No problems from my Dealership to get them changed.
     
  13. Oct 12, 2012 at 11:24 PM
    #13
    ProForce

    ProForce [OP] Thin Blue Line

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    The sarcastic comments are not necessary here. If you guys are ok with simply spending money replacing (regardless how little) to fix Toyota's mistake, that's fine with me. But I do not think its right that I should even have to visit the dealership for something of this nature, let alone get the run around for it. Saying this is "normal wear and tear" is beyond irrational and just straight ridiculous. I would love for Toyota to list a single vehicle in the history of the world that had headlights listed as a serviceable item due to wear like brakes. That's insane.

    In regards to the bulb killing someone, it does sound extreme I'll give you that much, but clearly you guys have never seen a vehicle electrical fire, or what melted plastic is capable of. Call me crazy, but mark my words, one day, it will cause a fire.

    The plastic on these headlights are not some cheap flimsy eBay housing plastic, this is DOT approved lenses which require a pretty high amount of heat resistance and protection. For a lens to melt from an OEM bulb is clearly a safety hazard. And even if it was safe, I didn't pay $32,000 for a brand new truck just to be told I have to spend an additional $550+ every 1-3 years for new headlights, and now inspecting my headlights for possible electrical hazards every trip to ensure I am safe.




    Sorry for the very long OP, for those who don't want to read the entire thing, no problem. Glad your dealership didn't give you a hassle. Unfortunately though for some of us, we aren't so lucky.
     
  14. Oct 12, 2012 at 11:24 PM
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    ProForce

    ProForce [OP] Thin Blue Line

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    Great to know! Thanks.
     
  15. Oct 12, 2012 at 11:28 PM
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    ProForce

    ProForce [OP] Thin Blue Line

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    For those who think I am overreacting or feel it is OK to have these types of safety hazards on a brand new vehicle, please keep these opinions and smart remarks to yourselves. I for one know that I am not alone in this, and I'm quite upset at the situation. I plan to use this thread to help my claim with Toyota, as well as help others in the same predicament. I don't need negative remarks diminishing the value of this thread for us in need. If OP is too long, don't read it, but no need to share, I know its long.
     
  16. Oct 12, 2012 at 11:33 PM
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    joes06tacoma

    joes06tacoma Well-Known Member

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    My 2006 does not have DRL.

    My work truck (09 regular cab 2WD Tacoma) has been slowing melting the lens on the left headlight for the last 30K plus miles. It currently has 70K on it. I just noticed this week that the right headlight is starting to melt as well. I recently replaced the left side DRL/signal bulb with the standard replacement from OReily. I am unaware of what cooler bulb to use to stop further damage to the lights. My employer purchased this truck almost exactly four years ago now. It's rarely driven for more than 45 mins at a time, so it doesn't take several hours of driving to heat the lens up to the point of damage. It's a company truck, so it's unlikely anything will be done as long as the lights still work.as

    Edit: At 80K now, the 09 has actually cracked one inner lense (left). I cut the wire under the dash as described in the "stealth mode" mod. It may not be my truck, but it will be me who has to hassle with it when the lights stop working.
     
    Last edited: May 23, 2013
  17. Oct 12, 2012 at 11:35 PM
    #17
    OZ-T

    OZ-T All of those moments....will be lost.....in time

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    Interesting , there is no sign of melting at all on my '09
     
  18. Oct 12, 2012 at 11:42 PM
    #18
    ProForce

    ProForce [OP] Thin Blue Line

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    Mine took 3 years and 3 months to show any signs of melting. It doesn't always happen right away, or even at all. At some point however, there is a pretty high chance of you eventually experiencing this problem.
     
  19. Oct 13, 2012 at 12:15 AM
    #19
    OZ-T

    OZ-T All of those moments....will be lost.....in time

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    I keep checking , it's been 4 years this month
     
  20. Oct 13, 2012 at 12:39 AM
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    NWTacoGuy

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