Twins... what if you checked the wiring and it was damaged/chaffed. (meaning you would need a new headlight for loads of$$$) Didn't you and someone else figure out a way to pull apart the headlight? You may be able to repair the wiring and save yourself from buying a new light. (how good are you with a soldering iron?)

Worst case scenario, you still need a new headlight. :dunno:

What I'm saying is I don't know if the stepper motor is replaceable. Like is it integrated to the HL so well I can't disconnect it and just replace it. :dunno:

It suprises me that the dealer would just replace something if you can repair it. I guess they just want to make money since they're not eating it.

I can patch wiring and solder. Won't be nice looking but it'll do! :D

I'm not 100% certain of the reason behind it, but realize that the xenon system is a high voltage system (certainly not 12 volt) and that in allowing a wire repair to take place they are taking a big chance in terms of quality control and safety. Thus in such a case a total replacement is the wiser option.

I don't think the problem is with the high voltage wiring or the stepper motor itself... I think the ground wire to the stepper motor and whatever else gets damaged. In what case a soldered and heat shrinked repair would be fine. The reason for replacement would be that you can't officially open the headlights to access the inside for repairs.

Sounds plausible. So many possibilities I guess from their vantage point it makes sense.

ive nevered used solder on any bmw ive worked on.

1) its not bmw approved
2) it introduces high resistance
3) it just doesnt look right.

So does that mean all electrical work/installs/repairs are wires crimped to connectors with no soldering? If so can you recommend a good crimper or the one BMW specs?

Thanks for the info. and it's good to know. I'm not too worried about #1 & #3.

#2 I don't know enough to say it doens't matter as much. Will higher resistance eventually lead to damge to the electronics? For arguments sake, if it's just the wiring to the stepper motor - is that different from like say a higher voltage/power/amperage or whatever than like if its for the HID wiring?!

Probably means no crimpers .. just replacement.

No, I've definitely seen BMW write-ups including retrofits with crimping involved. Often in electronics one also solders the connector to the wire for add strength and dependable electrical connection.

As far as #2 goes, the higher resistance you introduce the greater the load and so you'll pull more current, generate more heat, etc. until the sucker finally fails or the battery craps out quicker.