M-Class (W163) Produced 1998-2005: ML 230, ML 320, ML 350, ML 400 CDI, ML 430, ML 500, ML 270 CDI

Erratic Headlight Problems

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Old Nov 2, 2015 | 01:57 PM
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2001 ML320, 2010 S550, 2012 E350, 2015 C300 (All 4Matic vehicles)
Erratic Headlight Problems

I have a 2001 ML320. My headlight low beam would alternate functioning, one side would work only and then the other would. I could see the light flicker for a few seconds before it turned off. Now, even the high beam would light up at low intensity while in low beam setting which also rotates functioning one at a time. Even the daytime running light would alternate working, too. Occasionally, everything would work. The headlights have been working flawlessly for over 7 months.

The headlight assembly is an aftermarket Depo headlight with The Retrofit Source 50W Morimoto ballast and a D2S based Bi-Xenon projector. The only change I made was installing an aftermarket backup camera and parking sensors in July. In Aug, I started noticing headlight working intermittently.

I have already swapped out between left and right assembly bulbs and the complete HID kit. Same problem. I noticed the headlamp wiring harness connector's ground wire pin looks browned out or rust for both L & R connectors. I wonder if a short I had during the backup camera install might have affected it, the short had been corrected since. Also, I wonder if the 50W ballast might be too strong and have contributed to the problem. I have taken the 50W both ballasts out, the problem still persists - high beam still lights up at low intensity while in low beam setting.

Weird problem, please help.

Thanks,
John

Last edited by jt-hifi; Nov 2, 2015 at 02:30 PM.
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Old Nov 2, 2015 | 09:23 PM
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2001 ML320, 2010 S550, 2012 E350, 2015 C300 (All 4Matic vehicles)
Problem solved! It was a recessed pin of the right headlight assembly connector that caused the erratic/intermittent problem. I pulled the pin outward until it clicked and locked tight. Everything is working as it should now, yippee!

Last edited by jt-hifi; Nov 2, 2015 at 09:26 PM.
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