This is driving me insane!!

I have S4 Headlights (D2S) and I have a huge problem, its always the issue of one of my headlights not wanting to turn on either left or right, I've ordered new bulbs, its not the bulbs. I'm using DDM 55w ballasts, its not the ballasts (i've plugged in my VVME 35w ballast) and still, it doesn't want to turn on..

I've also unplugged the headlight levelers since I have an A4 and they are pointless, I've tried with them plugged in and without them plugged in. Nothing different really.. if not probably made things worse..

For me to get anything done I have to flick my headlights on/off at least 5-10 times to get maybe 1 headlight to turn on? Sometimes nothing will turn on, sometimes one.. sometimes both, its all random..

Heres things I know:
-Wiring is fine because when they are on and I'm driving theres no issue of them flickering or getting a bad ground, etc. I've also redid my wiring twice now.
-Not the bulbs (bought a second set, having the same issue)
-Not the ballasts (plugged in extra working ballast) and still having same issues
-Also both ballast are buzzing like normal when headlight switch is on, however the headlight doesn't lite.
-not the fuses (checked and they aren't blown, also tried upgrading to 20amp fuses and that didn't work, reverted back to 15amp).
-When I can get them to actually both come on, theres never an issue of them flickering or shutting off on me.
-Not headlight switch because high beams work, and lights worked perfectly fine till I cut out stock ballasts and installed aftermarket.....
-Would make no sense for a hid relay harness because I've had H7 DDM 55W in with no issues in the past, and 35W VVME H7 in the past with no issues.. D2S can't be using so much more power then an H7.

I mean, the car was made for H7 headlights and I'm using D2S Headlights on them.. could this effect anything?

When I had the STOCK ballasts & bulbs (D2S) in I had no issues whatsoever.. then I goto aftermarket bulbs and now I'm having issues.

I'm not really familiar with D2S connectors but I managed to get it on there without any issues. However I remember there are 4 side cuts for the d2s connector to connect to the bulb.. which only has 2 little pokes on the sides when it sits in the housing... Is there multiple ways to put it on? I put it on so it would fit properly closed it up and sometimes they work

ALSO in the past I've had Depo Headlights w/ DDM 55W HIDS and never had any issue turning them on and off, they always worked! My car can handle the power, but whats wrong?! >_<!

 

if your car came stock with the stock ballasts they are only 35w that could be a problem

 

having to flick the lights on and off a bunch of times to get them to come on sounds like a bad combi switch, but i'm pretty sure that would be all or none, not one or the other or none like you're describing.

 

are all the other electronics working perfectly? do you have the same problem if you try turning them on after driving for a little while or just before driving? maybe it could be a problem with your battery if it's old or not charged all the way..

 

Today I went down to autozone, bought 2 new 9006 connectors & crimps, did all the electric work, made sure everything was nice and snug, etc. Tucked it all back in, and I'm having the same issue with my 55W DDM kit, also tried the VVME 35w ballast and I'm having the same issue.

Battery is new, its not the switch.. The switch wouldn't magically blow up within 5 minutes of me taking out my OEM Ballasts and putting in aftermarket.

At this point I'm thinking I need a relay harness sadly.. I'm only having starting issues.. and I need this fixed asap.

 

If you had D2S HIDs working why switch them for DDM H7s? Aren't these kits designed for those who have stock halogens to upgrade to HID? A4s with stock HIDs were also D2S so I would use the bulb the housing was designed for. (sounds like you're using H7s in D2S housings?) Seems like a headache considering you say the D2S' were working perfectly before.... I would just go back to using D2S'.

 

I had OEM a4 1 piece projector headlights w/ vvme 35w hids, sold em, bought depo euro headlights put ddm 55w in there, sold them. got my hands on OEM S4 B5 headlights, put them in w/ stock ballasts & headlights, headlights were very old and dim, took out the ballasts and sold them, took out the bulbs and threw em away. Bought a DDM 55W kit installed it with no issues, and one headlight comes on, or both don't sometimes. I'm using D2S bulbs in a D2S housing.. obviously.. I've triple checked my wires and re-crimped.

Its not the ballast because I've tried VVME ballast, had same issues. Its not the bulb because I've bought a new pair of bulbs, same issues. Its not the headlight switch because why would it randomly stop working between the time I cut out the stock ballasts and put in aftermarket? Which leaves me to believe I'm having power issues upon start... therefore I bought a relay harness off eBay, 20amp fuse, and 40amp relay.. this is the final thing it could possibly be, I've gone threw and diagnosed everything else... Theres a power issue for some reason..

Maybe the stock wiring cannot handle aftermarket ballasts (for some reason idk), I've heard horror stories of people having somewhat of the same issue as me and installing the relay and all the problems went away.. Its recommended for any aftermarket HID installation that you use a relay. Most people don't, I never have, never thought I would even need one.. But this way my HIDs will be running directly off the battery once I flick the switch on.. Which if it works, I'll be getting more steady electric flow, and I've heard people saying their HIDs are slightly brighter then before after using the relay harness because you are getting direct power from the battery vs the stock housings.

 

I think that sounds like a good plan. Install the relay and let us know how it goes. Good luck!

 

I made my own relay harness because I got impatient for mine to come in the mail.. Relay harness did nothing.. Used 40amp relay, 20 amp fuse... Maybe I got 2 sets of bad bulbs from DDM? rofl. or maybe my relay harness is just fail? I followed the guide http://forums.vwvortex.com/zerothread?id=2632686. The relay harness I bought online is wired a little different..:/ http://i223.photobucket.com/albums/d...ng-harness.jpg
I resoldered on 9006 connectors, same issue still, either it doesn't come on, or they flicker on. then stay steady.

I'd like to believe I need a relay harness.. however even if I only have 1 headlight plugged in.. sometimes it won't even light the 1 headlight.. the cars stock harness should have enough power to light 1 headlight w/ an aftermarket ballast.... at this point I'm thinking DDM sent me 2 sets of crap bulbs! =(

Turn light switch, both ballasts buzz, sometimes 1 light comes on, sometimes none. Ballasts are working, they are doing normal buzzing.. switch is working because ballasts are igniting the second I flick it. Wiring is fine because when I flick the switch the connection is good and ballast turns on.. Ballast turns on.. but lights don't.. After 5+ times of flicking them on and off I can possibly get both to be lit... I've made my own relay harness and the same symptoms happened even though it ran directly off battery power... At this point I'm thinking I got another defective set of D2S Bulbs?

 

remove the aftermarket hid ballast and bulb your using. Use test leads for positive and negative, and connect directly to the battery. If both bulbs come as designed, as they should, right away or after a 3 second warm up, then your problem, unfortunately, is car wiring. Audi, as beautiful and fun to drive cars they are, have a complex wiring system. I personally wouldn't be able to explain beyond what you have already mentioned. You have tried everything I would try, except i would try the above. This is of great interest to me as I'm thinking of buying the HELIX aftermarket e-codes of partsforeuro.com that have the d2s low and h7 high and the w5w city light. And I plan on putting HID's obviously. I already had a 55W HID system on my previous car, but it was a 9006, so i just have to buy d2s bulbs. Let us know what happen......cause if that works.....than i'll be forced to dig like a greyhound and nit pick the electrical system..........................freakin' audi...........................i love them though!!!!!!!