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My driver side headlight started randomly going off recently, then completely failed. I assumed it was the bulb and was about to purchase some replacement HID bulbs. While searching, I found a video on YouTube of a guy with the same problem. Turns out the light wasn't bad, but the 20amp micro stubby fuses (#15 for the drivers side and #16 for passenger side) were melted. HE replaced his fuses and the lights worked, but he never explained what caused them to fail. So, I pulled fuse #15 and sure enough it was burned. I replaced it with a new replacement and my headlight works again. I don't know if anyone else has experienced this, but I wanted to share it so others can be aware of it. It's much cheaper to replace a $1.50 fuse than to replace the $68 HID bulb.
 

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HID owner here and I’ve also had no trouble from mine after 48,000 miles. I’m very curious as to what was causing the fuses to melt! I’d have it looked at!
 

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HID bulbs become less efficient as they age and require progressively higher voltage to "fire". That five-year-old bulbs might start to burn fuses isn't that surprising.
 

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My driver side headlight started randomly going off recently, then completely failed. I assumed it was the bulb and was about to purchase some replacement HID bulbs. While searching, I found a video on YouTube of a guy with the same problem. Turns out the light wasn't bad, but the 20amp micro stubby fuses (#15 for the drivers side and #16 for passenger side) were melted. HE replaced his fuses and the lights worked, but he never explained what caused them to fail. So, I pulled fuse #15 and sure enough it was burned. I replaced it with a new replacement and my headlight works again. I don't know if anyone else has experienced this, but I wanted to share it so others can be aware of it. It's much cheaper to replace a $1.50 fuse than to replace the $68 HID bulb.
It's a Bad Connection from the fuse to the fuse box...you could put a little solder on the fuse to make the connection a little tighter! This is what I found when I found out that my fuses we're burning up!
 

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OK, so I'm thinking that the reason the fuses take so long to blow is because there is an initial surge of power. Not enough to blow the fuse, but over time it weakens the fuses and makes them eventually blow. Does that seem reasonable?
 

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My driver side headlight started randomly going off recently, then completely failed. I assumed it was the bulb and was about to purchase some replacement HID bulbs. While searching, I found a video on YouTube of a guy with the same problem. Turns out the light wasn't bad, but the 20amp micro stubby fuses (#15 for the drivers side and #16 for passenger side) were melted. HE replaced his fuses and the lights worked, but he never explained what caused them to fail. So, I pulled fuse #15 and sure enough it was burned. I replaced it with a new replacement and my headlight works again. I don't know if anyone else has experienced this, but I wanted to share it so others can be aware of it. It's much cheaper to replace a $1.50 fuse than to replace the $68 HID bulb.
I had the exact same experience this year with my 2015 Charger R/T Road & Track. In April, my driver-side high and low beams were inoperative regardless of switch position (ON or AUTO). On a whim I swapped fuses 15 and 16 – both of which looked fine – and the light started working again. Puzzled but satisfied, I moved on. However in June, I noticed my passenger-side headlight now exhibited the same problem. This time though, fuse 16 was warped and partially-melted, though oddly it still showed continuity. I replaced it and the headlight began working again. In my case I'm guessing the fuse was defective as my driver, then passenger, light outages seemed to follow it.
 

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It's a Bad Connection from the fuse to the fuse box...you could put a little solder on the fuse to make the connection a little tighter! This is what I found when I found out that my fuses we're burning up!
You are correct. My 2015 Charger Rallye with 38K miles does the same thing. When it happens, I just tap the fuse box and it comes back on. Through other testing (relay and fuse swaps), I've narrowed it down to a bad connection within the fuse box. I just haven't had the time to open it and do any soldering. I have a similar problem with my Adaptive Cruise Control/Accident Avoidance system randomly shutting down and telling me to clean my front radar sensor. I'm led to believe it is a similar bad connection inside the fuse box at the fuse terminal. Soon, I'll be opening up the fuse box and checking both.
 

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My driver side headlight started randomly going off recently, then completely failed. I assumed it was the bulb and was about to purchase some replacement HID bulbs. While searching, I found a video on YouTube of a guy with the same problem. Turns out the light wasn't bad, but the 20amp micro stubby fuses (#15 for the drivers side and #16 for passenger side) were melted. HE replaced his fuses and the lights worked, but he never explained what caused them to fail. So, I pulled fuse #15 and sure enough it was burned. I replaced it with a new replacement and my headlight works again. I don't know if anyone else has experienced this, but I wanted to share it so others can be aware of it. It's much cheaper to replace a $1.50 fuse than to replace the $68 HID bulb.
Thank you! Thank you! Thank you! Wish I would have checked that before buying the headlights, but at least now I have a spare set...
 

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I had the same issue a while back (under warranty). Took it to the dealer, they replaced the light and of course the issue continued. I went through the fuses and saw that both of my HID fuses were melted. I brought this to the attention of the dealer. They took pictures and sent them off to FCA.
 

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Hello all. I just had the same exact issue occur! About a week ago my front right headlight did not come on when using the key fob to unlock the doors. The headlight was out that day then began working again that night. I was unable to replicate the problem for several days. Then the headlight went out again. My first instinct was to replace the bulb. It turns out this HID bulb is very expensive. $275 at the dealership and $175 at the local parts store. The dealership urged me to pay $150 for a diagnostic fee to identify the problem. Thankfully before purchasing anything I read this forum!

I checked out the #15 and 16 fuses and sure enough the #16 was melted. For $3 I purchased a package of 20 amp fuses at Advanced Auto Parts and replaced the bad fuse. Suddenly the headlight was working again! I saved several hundred dollars minimum and lots of time by reading the advice here. The dealership likely would have replaced the bulb, or at worst charged for the entire light assembly to be replaced. I read somewhere that this happened to someone and the problem still persisted.

My only concern now is that the wiring connection to the fuse box is faulty and that the same issue may arise again. How difficult is it to fix this? Is soldering necessary?
 

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Hello all. I just had the same exact issue occur! About a week ago my front right headlight did not come on when using the key fob to unlock the doors. The headlight was out that day then began working again that night. I was unable to replicate the problem for several days. Then the headlight went out again. My first instinct was to replace the bulb. It turns out this HID bulb is very expensive. $275 at the dealership and $175 at the local parts store. The dealership urged me to pay $150 for a diagnostic fee to identify the problem. Thankfully before purchasing anything I read this forum!

I checked out the #15 and 16 fuses and sure enough the #16 was melted. For $3 I purchased a package of 20 amp fuses at Advanced Auto Parts and replaced the bad fuse. Suddenly the headlight was working again! I saved several hundred dollars minimum and lots of time by reading the advice here. The dealership likely would have replaced the bulb, or at worst charged for the entire light assembly to be replaced. I read somewhere that this happened to someone and the problem still persisted.

My only concern now is that the wiring connection to the fuse box is faulty and that the same issue may arise again. How difficult is it to fix this? Is soldering necessary?
Definitely want to solder the connection as it will probably keep happening with blowing fuses. Not many experience this issue and I haven't either except for in one of my cars that I've owned and soldering the connections fixed the issue. It's not that difficult to do and if you've ever soldered anything, you shouldn't experience any issues...if not, there are plenty of vids online that can show you. As above have stated, it also has to do with the bulb and how long you've had it, the older the bulb the more power it will require to fire up and therefore draws more power, which on a bad connection to the fuse box will always end badly!

Hopefully this has helped...
 

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A question for those of you with issues; are all the problems on cars with factory HID's, or are any of them on cars with aftermarket conversions?
 

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I lost both of my headlamps at the same time. I opened up the fuse box and both 15 and 16 were melted. I swap the fuses with new ones and everything's been working fine ever since.
 

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Mine too. First it was just one but then both went out, at night, driving down the road. The price of HID bulbs had me nauseous. Thankfully I noticed them flicker through the ring doorbell recording. Changed the fuses and haven’t had a problem.
 
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