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Old 09-29-2016, 02:20 PM   #8
Hot Wheels
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Join Date: Mar 2016
Drives: 2014 WRB BRZ Limited
Location: Garden City, KS
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Ok everyone I found the solution and I wanted to post it here for those in the future who may have this problem.

Short answer, two pins corroded and were touching when they shouldn't have.

Long answer:
Each headlight housing contains several pieces. The plastic housing, the bulb, the ballast, an O-ring, and the wiring. After removing the front bumper, I put in fresh fuses for the headlights and unplugged both lights. I switched the light to on, and neither fuse popped. I plugged in passenger side and turned on - no popping. I unplugged passenger and plugged in driver side - They popped.

I then removed the driver's side headlight unit and poked around. The ballast screws onto the bottom of the unit via 4 screws. After undoing them I saw that the ballast was covered in corrosion. I think the O-ring was leaking water into the unit.

I replaced the ballast with a new one, but there is a red and black wire that plug into the ballast with a funky looking clip. They were also corroded, so I got a new set of that wire and clip and cut/soldered it into place. with new ballast installed, I replaced the bad O-ring and put silicone paste all around the ballast just to be sure no moisture gets in again. Connect everything back up and it's working fine.

When I bought the car, the previous owner had installed a crap HID kit and underglow. It really messed my whole electrical system up. I now realize that they installed the HID when they didn't want to fuss with getting it fixed the proper way with OEM parts like I did. The Hi and low beams, eyebrow, and fogs all work as intended, but the DRL for some reason come on with the hi beams, and not just when driving. I'm afraid this is as close as I am going to get to fixed.
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