How to replace ballast on passenger side?

nj335i · 12-30-2011, 06:24 PM

I have a 335 sedan with oil cooler and it seems impossible to replace the ballast myself (for stock xenon headlights). Any tips from someone who has done this before? Are there special tools (smaller ratchet wrench) that could aid in the process? The oil cooler hoses and some other stuff are in the way and I can't seem to reach the screws well enough to turn them...

Any input would be welcome!

kevin@bavarianx · 12-31-2011, 02:34 AM

Removing the bumper and then the headlight would be best option.

nj335i · 12-31-2011, 07:11 AM

Yikes, not what I wanted to hear. Ok, I guess it's going to a shop because that sounds like more than I want to get into.

fdriller9 · 12-31-2011, 07:24 AM

Maybe losses the oil cooler and move it out of the way? Not sure if thats possible but worth a shot.

A shop will charge you at least 1 hour labor, most likely 2 hours.

nj335i · 01-01-2012, 11:29 PM

Decided to take it to a shop. Didn't feel like going through the trouble. Will let you know how it turns out.

xacoffeemx · 03-24-2012, 04:38 AM

I was able to change the ballast on the passenger side and both pair of bulbs without taking out the wheels, jacking up the car, nor removing the bumper.

I have a 06 e90 with sports package and I had enough room to change the ballast when I turned the steering wheel completely to the right.

The trick is.. I got a 1.5cm long hex bit that fit the screw for the ballast and used a wrench to turn it about 10 degrees per turn... It was a bit of a work, but eventually I was able to get the screw out.

The hardest part was taking out the ballast from the socket of the headlight assembly because there is a rubber seal and a screw that holds the ballast very tight from sliding out.

But I found a trick to that as well:
First you take off the HID wire from the ballast (it's hard, but it's possible. MAKE SURE YOURE NOT PULLING ON THE WIRE, BUT YOURE PULLING ON THE METAL PIN CONNECTOR)
Then just pull the ballast away from the headlight assembly, towards the drivers side. Don't worry about the other wire connector as it's long enough to handle this
Once you pull the ballast away from the ballast socket, and the rubber seal is completely out, slowly but with a little bit of strength, slide the ballast out towards the rear of the car until the second wire connector is visible from the outside of the assembly.
Once the second wire connector is visible, get a hook tool or something of sort to unlatch the wire connector before pulling it out. Once you get both of the connections out, slide out the ballast and you just successfully removed the ballast.

Make sure you take out the rubber seal band from the old ballast and put it on the new one if the new ballast does not come with the rubber seal.

Do the steps backwards and you can easily put the new ballast..

Putting the ballast in isn't as hard as taking it out..

It took me exactly two hours to replace one passenger ballast and change both of the d1s bulbs and it did not require me to do any wheel removing, jacking up the car, nor removing the bumper...

I'm sure a lot of people might not recommend the method that I used, but I was able to do the job without damaging the car in the end

xacoffeemx · 03-24-2012, 04:41 AM

If someone needs pictures of how this was done, I will gladly do this process over to help the people in need... I wasn't able to find any DIY this way and was stumped at the weekend project myself

rjive · 04-18-2012, 01:49 PM

Quote:

Originally Posted by xacoffeemx

If someone needs pictures of how this was done, I will gladly do this process over to help the people in need... I wasn't able to find any DIY this way and was stumped at the weekend project myself

I would love to see some pics. That's a pain though so I understand if your motivation isn't there.

tcharged · 04-28-2012, 12:08 AM

Could I see some pics here??

xacoffeemx · 05-02-2012, 01:01 PM

Quote:

Originally Posted by rjive

I would love to see some pics. That's a pain though so I understand if your motivation isn't there.

Quote:

Originally Posted by tcharged

Could I see some pics here??

Sorry I wasn't on the forums for quite a while lately.

When I'm home tomorrow, I will try to get pictures posted

rjive · 05-13-2012, 01:47 PM

Quote:

Originally Posted by xacoffeemx

Sorry I wasn't on the forums for quite a while lately.

When I'm home tomorrow, I will try to get pictures posted

Looking forward to it. I need to find a ballast replacement part as well. Anyone have a suggestion on where I can find that?

I need the drivers side though.

Midnightfang · 07-11-2012, 10:09 AM

i have the same issue, any updates on the pictures?

rentonrider · 10-17-2012, 08:42 PM

When replacing the ballast, is it plug and play? Or does your car need to be reprogrammed? Thanks.

rjive · 02-05-2013, 08:09 PM

Anyone have any updated pictures or additional information to share?

The Koz · 02-23-2013, 12:05 PM

Anyone out there who can advise me how to replace the ballast? A Tech friend of mine helped me try changing the bulb (D1S) twice first to no effect?

The ballast is attached to the side of the light and has three bolts; two are accessible the third slot appears that you would need to take out the headlight and it looks like two torque bolts on top should do it? Checking?

Dealership is telling me that it's two hours labour (after a $135 diagnosis) to re and re the ballast and that you have to take out the headlight, hoist the car and remove the bumper just to get at one bolt?+ cost of part around $625 (saw on ebay for around $300? Where is the best online store or local Toronto store to buy?).

My light flickered and was weaker than the right side and then went out completely. The bulb has the igniter as part of it, so that rules out that possibility.

Was thinking that it might be best to swap out the working ballast to the driver's side to test to confim issue? I guess it could be a wiring issue or whole light assembly? Unlikely I think, as all the other lights are working (turn signal and parking lights etc.)

Would appreciate some guidance from the Bimmer Pros out there I'm technical and handy but have not worked on a BMW before.

Thanks in advance!

Steve

Smurfzilla · 06-25-2016, 03:05 PM

I know I'm dredging this up form the dead, I'm not extremely well versed in bmw 3 series butbi do not see how it's possible to pull the passenger side ballast out. I have tried and the problem is you cant get the ballast far enough away from the headlight to disconnect the cables going to it. There was enough space to pull it away to see the edge of the ballast where the rubber o ring is but it won't come past that point. Without pictures I can only assume there are subtle differences between the 06 and the 08. If I'm wrong a bit of direction would be much appreciated.

svt1998gt · 08-27-2016, 06:44 PM

I know this doesnt help but i feel pulling the bumper and headlights is the best option. While you are in there and saving the money put those funds on upgrading the halo bulbs to the 6500k versions. Looks really nice. I found the ballast on ebay for 50 bucks and was listed as brand new. I know some folks have had to reprogram the ballast but i didnt have to do that so I dont know what i did different but it was plug and play for me.

Let me know if anyone has a good recommendations for the foglights the yellow needs to go.

Thanks,

aleksandre90 · 09-25-2018, 05:56 PM

I was just able to pull it out without taking off the passenger rim or bumper, my passenger low beam was not working correctly and was Turing on and off, I was able to look at the small black and yellow wires and see that they were exposed so I pulled the little pins out of the connector and put some heat strink on the wires to fully enclosed them so they don’t short out, so far low beam is working! 😁

12-30-2011, 06:24 PM	#1
nj335i Modaholic 88 Rep 1,705 Posts Drives: with 3 pedals Join Date: Jan 2007 Location: East Coast iTrader: (7)	How to replace ballast on passenger side? I have a 335 sedan with oil cooler and it seems impossible to replace the ballast myself (for stock xenon headlights). Any tips from someone who has done this before? Are there special tools (smaller ratchet wrench) that could aid in the process? The oil cooler hoses and some other stuff are in the way and I can't seem to reach the screws well enough to turn them... Any input would be welcome! __________________ Euro Delivery - April 2007
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12-31-2011, 02:34 AM	#2
kevin@bavarianx Banned 33 Rep 812 Posts Drives: E36 M3 Join Date: Jul 2010 Location: Brea, CA iTrader: (3)	Removing the bumper and then the headlight would be best option.
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12-31-2011, 07:11 AM	#3
nj335i Modaholic 88 Rep 1,705 Posts Drives: with 3 pedals Join Date: Jan 2007 Location: East Coast iTrader: (7)	Yikes, not what I wanted to hear. Ok, I guess it's going to a shop because that sounds like more than I want to get into. __________________ Euro Delivery - April 2007
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12-31-2011, 07:24 AM	#4
fdriller9 Banned 252 Rep 7,089 Posts Drives: '06 AW 330xi Join Date: Mar 2009 Location: North Jersey/Philly/NYC iTrader: (4) Garage List 2006 330xi [6.44]	Maybe losses the oil cooler and move it out of the way? Not sure if thats possible but worth a shot. A shop will charge you at least 1 hour labor, most likely 2 hours.
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01-01-2012, 11:29 PM	#5
nj335i Modaholic 88 Rep 1,705 Posts Drives: with 3 pedals Join Date: Jan 2007 Location: East Coast iTrader: (7)	Decided to take it to a shop. Didn't feel like going through the trouble. Will let you know how it turns out. __________________ Euro Delivery - April 2007
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03-24-2012, 04:38 AM	#6
xacoffeemx Private 33 Rep 57 Posts Drives: 2017 320i, 2020 M340i Join Date: Dec 2011 Location: CA iTrader: (1)	I was able to change the ballast on the passenger side and both pair of bulbs without taking out the wheels, jacking up the car, nor removing the bumper. I have a 06 e90 with sports package and I had enough room to change the ballast when I turned the steering wheel completely to the right. The trick is.. I got a 1.5cm long hex bit that fit the screw for the ballast and used a wrench to turn it about 10 degrees per turn... It was a bit of a work, but eventually I was able to get the screw out. The hardest part was taking out the ballast from the socket of the headlight assembly because there is a rubber seal and a screw that holds the ballast very tight from sliding out. But I found a trick to that as well: First you take off the HID wire from the ballast (it's hard, but it's possible. MAKE SURE YOURE NOT PULLING ON THE WIRE, BUT YOURE PULLING ON THE METAL PIN CONNECTOR) Then just pull the ballast away from the headlight assembly, towards the drivers side. Don't worry about the other wire connector as it's long enough to handle this Once you pull the ballast away from the ballast socket, and the rubber seal is completely out, slowly but with a little bit of strength, slide the ballast out towards the rear of the car until the second wire connector is visible from the outside of the assembly. Once the second wire connector is visible, get a hook tool or something of sort to unlatch the wire connector before pulling it out. Once you get both of the connections out, slide out the ballast and you just successfully removed the ballast. Make sure you take out the rubber seal band from the old ballast and put it on the new one if the new ballast does not come with the rubber seal. Do the steps backwards and you can easily put the new ballast.. Putting the ballast in isn't as hard as taking it out.. It took me exactly two hours to replace one passenger ballast and change both of the d1s bulbs and it did not require me to do any wheel removing, jacking up the car, nor removing the bumper... I'm sure a lot of people might not recommend the method that I used, but I was able to do the job without damaging the car in the end
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03-24-2012, 04:41 AM	#7
xacoffeemx Private 33 Rep 57 Posts Drives: 2017 320i, 2020 M340i Join Date: Dec 2011 Location: CA iTrader: (1)	If someone needs pictures of how this was done, I will gladly do this process over to help the people in need... I wasn't able to find any DIY this way and was stumped at the weekend project myself
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04-28-2012, 12:08 AM	#9
tcharged Banned 27 Rep 299 Posts Drives: bunch of them Join Date: Apr 2012 Location: Toronto iTrader: (1)	Could I see some pics here??
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07-11-2012, 10:09 AM	#12
Midnightfang Private First Class 13 Rep 100 Posts Drives: C63 AMG, ML350, E90 330i Join Date: Oct 2010 Location: Houston, TX iTrader: (2)	i have the same issue, any updates on the pictures?
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10-17-2012, 08:42 PM	#13
rentonrider Banned 32 Rep 411 Posts Drives: E92 M3 Join Date: Sep 2011 Location: Renton, WA iTrader: (2) Garage List 2011 BMW M3 [7.00]	When replacing the ballast, is it plug and play? Or does your car need to be reprogrammed? Thanks.
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02-05-2013, 08:09 PM	#14
rjive weekend > work 0 Rep 63 Posts Drives: 2008 BMW 335i Join Date: Jun 2011 Location: California iTrader: (0)	Anyone have any updated pictures or additional information to share?
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02-23-2013, 12:05 PM	#15
The Koz Registered 0 Rep 3 Posts Drives: 2008 BMW 335 XI Join Date: Feb 2013 Location: Barrie, ON iTrader: (0)	Anyone out there who can advise me how to replace the ballast? A Tech friend of mine helped me try changing the bulb (D1S) twice first to no effect? The ballast is attached to the side of the light and has three bolts; two are accessible the third slot appears that you would need to take out the headlight and it looks like two torque bolts on top should do it? Checking? Dealership is telling me that it's two hours labour (after a $135 diagnosis) to re and re the ballast and that you have to take out the headlight, hoist the car and remove the bumper just to get at one bolt?+ cost of part around $625 (saw on ebay for around $300? Where is the best online store or local Toronto store to buy?). My light flickered and was weaker than the right side and then went out completely. The bulb has the igniter as part of it, so that rules out that possibility. Was thinking that it might be best to swap out the working ballast to the driver's side to test to confim issue? I guess it could be a wiring issue or whole light assembly? Unlikely I think, as all the other lights are working (turn signal and parking lights etc.) Would appreciate some guidance from the Bimmer Pros out there I'm technical and handy but have not worked on a BMW before. Thanks in advance! Steve
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06-25-2016, 03:05 PM	#16
Smurfzilla Private First Class 22 Rep 150 Posts Drives: E90 335i Join Date: Jun 2016 Location: Raleigh iTrader: (0)	I know I'm dredging this up form the dead, I'm not extremely well versed in bmw 3 series butbi do not see how it's possible to pull the passenger side ballast out. I have tried and the problem is you cant get the ballast far enough away from the headlight to disconnect the cables going to it. There was enough space to pull it away to see the edge of the ballast where the rubber o ring is but it won't come past that point. Without pictures I can only assume there are subtle differences between the 06 and the 08. If I'm wrong a bit of direction would be much appreciated.
	Appreciate 0 Quote

08-27-2016, 06:44 PM	#17
svt1998gt Second Lieutenant 75 Rep 212 Posts Drives: 2008 e90 335i, 2012 X5 M spor Join Date: Aug 2013 Location: Texas iTrader: (0) Garage List 2012 BMW 550i M Sport [0.00] 2008 BMW 335i [0.00] 2012 BMW X5 M Sport [0.00]	I know this doesnt help but i feel pulling the bumper and headlights is the best option. While you are in there and saving the money put those funds on upgrading the halo bulbs to the 6500k versions. Looks really nice. I found the ballast on ebay for 50 bucks and was listed as brand new. I know some folks have had to reprogram the ballast but i didnt have to do that so I dont know what i did different but it was plug and play for me. Let me know if anyone has a good recommendations for the foglights the yellow needs to go. Thanks,
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09-25-2018, 05:56 PM	#18
aleksandre90 Registered 0 Rep 2 Posts Drives: 2006 BMW e90 330i Join Date: Mar 2018 Location: Fresno iTrader: (0)	I was just able to pull it out without taking off the passenger rim or bumper, my passenger low beam was not working correctly and was Turing on and off, I was able to look at the small black and yellow wires and see that they were exposed so I pulled the little pins out of the connector and put some heat strink on the wires to fully enclosed them so they don’t short out, so far low beam is working! 😁
	Appreciate 0 Quote