If the glass is broken as well, then I'd bet my next paycheck on thermal shock. Take off the housing and check for any leaks of the sort. Those bulbs can reach up to 200*F and if some 65*F water touches it, then you have recipe for disaster.

Consequently, if you saved the receipt and bought it from a place like Wal-Mart, you have a very good chance of getting it replaced.

Waiting for pictures

 

As promised, better late than never:

[IMG]C:\Users\TerryS\Downloads\photo.jpg[/IMG]

[IMG]C:\Users\TerryS\Downloads\photo2.jpg[/IMG]

I can't tell if the images are showing. But I checked the housing and it is solid, no excessive vibration. Looking more closely at the photos, now that it's getting lighter out, I can see the moisture in the housing.

If the photos are viewable, the first one is the passenger side and you can see the remains of the glass in the bottom. the second is the drivers side, no broken bulb, but you can clearly see the heat distortion on the lens.

 

Just in case, I out the photos in my garage:

https://www.f150online.com/forums/me...age+-+elf.html
P.S. I doubt I save any of the receipts for any of the bulbs...live and learn.

 

Wow they both are melted. You need new fog housings. Do you know exactly what kind of bulbs you were using ? I see some blue in the pax side housing

 

I had used the Sylvania Ultra's, I don't recall the wattage, bought from Auto Zone and Pep Boys. I can't imagine they would have been more than the std. 65w. The last set I bought from Amazon and I know those were 65w, because I just put them in last week. The blue was the color of the bulb tip.

I thought new housings was what I was looking at, although I have found some amber colored Halo replacements, they also come in clear and smoked, but I figured the amber would change the look as well as the color.

 

Well there is your problem.

65W 9005s WILL melt 2006-12 housings (as you evidently see). Your truck is supposed to use H10 9145 45W bulbs.

I bet they got so hot they melted and the pax side just got hot enough to separate and allow water inside.

 

Well thank you alex. You have confirmed what I thought and thank you for the clarification on the wattage for those replacements bulbs. I won't forget that lesson. Now I just need to decide which replacement path I'm going to take, Lenses and bulbs or Halo Projector direct replacements.

 

If you want looks (and actually like them), the halo projectors are what you want. Stock reflectors cast a much better beam. Or you could drop some serious coin and go a matchbox projector retro

 

Hi Alex,

So here is my update, based on your recommendations I went with a stock style replacement housing for better light dispersion. I got the housings on the big name aution site (not sure if I can use the name or not) with a buy now option for less that $20 each. I also got amber 42w bulbs for under $10/pair. finally got everything installed this week.

So far, everything is working great and the fog lights really light up the road ahead of me, not to mention the cool look of the 2 different colors. It's supposed snow/sleet/rain up here tonight, so come the real test.

While doing the work, I kept the mish-mash of odd ball bulbs I have left over now. I found the packaging for one of the Sylvania sets I replaced the bulbs with. Opps! Sylvania P/N: 9005 60w bulbs. I guess we now know for sure what caused all the problems melting the housings. It's like you said, the housing probably got SO hot, that the seal let go and the moisture got in, good call.

Here are a couple of pictures of what came out of the pass-side:





A special thanks to Alex for all your patience and help, I knew I came to the right place to get an answer. Maybe some day I'll be able to return the favor for someone else on this forum.

 

Seams to be a big problem. Mine and 3 or 4 others have this same problem. Some are running stock bulbs, some silverstars. 2 of them just bought brand new housings and they are still exploding bulbs. 3 out of 4 times the glass will explode. Only takes a month or so. I solved my issues by going to a PnP HID kit. Never had a problem. Now I've replaced those with D2S Mini's with a dedicated 3000k fowl weather bulb, Still no problems.

 

Yeah, I have seen those too, but was never sure how much of a pita they are to install. Though, your's look real nice because you can keep the stock look.

 

You're welcome. I'm glad you got it all figured out.