Dynamic Bending Light Failure

[Nedstand]

"This 200,000km /10 yr extended warranty is worth the $260 CAD I paid for it."
Did you get that extended warranty from the dealer or is it a third party warranty? That sounds like a really good deal... whereas the markup on those parts appears to be crazy.

 

[D.J.]

"This 200,000km /10 yr extended warranty is worth the $260 CAD I paid for it."
Did you get that extended warranty from the dealer or is it a third party warranty? That sounds like a really good deal... whereas the markup on those parts appears to be crazy.

Bought the car new,
Extended warranty through Kia "5 star Kia warranty"

There were significant negotiations on the warranty price, I think it was originally offered to me @ around $5,000.
I got it down to $2,601

 

[D.J.]

"This 200,000km /10 yr extended warranty is worth the $260 CAD I paid for it."
Did you get that extended warranty from the dealer or is it a third party warranty? That sounds like a really good deal... whereas the markup on those parts appears to be crazy.

Sorry, crazy typo. $2,601CAD

Not $260.

My bad

 

[Nedstand]

Thanks for clearing that up! I definitely would buy for 260 even in USD!

 

[Nedstand]

Job completed (I hope), and not a difficult DIY... and a damn good thing I checked, as the dealer did not change the moisture pack on the driver side (see photo) which was expanded and broke off the retaining clip. So I guess the dealer didn't fully read the TSB which clearly says to replace both sides.

I decided to double check the passenger side, and it has the new clip and a fresh moisture pack.
Question - Did they orient the clip properly? When I did the driver side, I put it the other way out so as to give the pack room to expand. The way they did it, with the prongs facing toward the pack, it seems to me like the pack has very little room for expansion. Does anyone know the proper orientation?

Some tips I from my DIY:

Use the clip removal tool (got one from Amazon) and order extra clips (14206-08250B). Use a fresh clip (i.e. don't try to reuse the old clip)
The access panel is pretty snug but one you get one edge started it's easy by hand to get the rest open.
The dust cap only requires a small turn (I thought it was screwed on), about 1/16 of a full turn. Then you have to work it a little as the O-Ring is holding it in place.
The most difficult part for me was getting it all back in place. There's an "open-close" label on the back of the cap. Make sure that is facing north, and work the top edge in first.

 

[ldusseau]

Ah hah! Thank you to mull0263 for posting that picture! I had the exact same thing happen just yesterday with my 2018 Stinger, Dynamic Bending failure that just started as the temperature dropped. I do remember seeing some moisture inside my right headlight on occasions, so I bet the desiccant swelled and is blocking the bracket from swiveling. My car is out of warranty though (bought it used) so I'm printing out the TSB and taking it to my indy shop. I'm not ready to drop $3600 on a new headlamp yet so keeping my fingers crossed.

 

[D.J.]

Ah hah! Thank you to mull0263 for posting that picture! I had the exact same thing happen just yesterday with my 2018 Stinger, Dynamic Bending failure that just started as the temperature dropped. I do remember seeing some moisture inside my right headlight on occasions, so I bet the desiccant swelled and is blocking the bracket from swiveling. My car is out of warranty though (bought it used) so I'm printing out the TSB and taking it to my indy shop. I'm not ready to drop $3600 on a new headlamp yet so keeping my fingers crossed.

both headlights? or right side only causing problems for you?

 

[ldusseau]

Not sure at this point. Haven't had it in yet to read the fault codes. However from all the comments and pictures I'm thinking I should have my shop go ahead and order new packs and vented covers for both headlamps. It won't hurt to replace both of them anyway. It's a hell of a lot cheaper than a full lamp replacement; the binding that would be caused between the cap and the swiveling component is something you don't want to continue. I'm a lighting engineer and moisture inside LED headlamps is a common issue we deal with. LED headlamps don't typically get as hot inside so the moisture doesn't "burn off" like in traditional halogen lamps, especially in the cold regions further away from the light sources. It's really common for countries in South America that have humid environments but get a little chilly in the winter. That's why there are desiccant packs now; changing them should be a normal service procedure, like changing cabin filters.

 

[D.J.]

Not sure at this point. Haven't had it in yet to read the fault codes. However from all the comments and pictures I'm thinking I should have my shop go ahead and order new packs and vented covers for both headlamps. It won't hurt to replace both of them anyway. It's a hell of a lot cheaper than a full lamp replacement; the binding that would be caused between the cap and the swiveling component is something you don't want to continue. I'm a lighting engineer and moisture inside LED headlamps is a common issue we deal with. LED headlamps don't typically get as hot inside so the moisture doesn't "burn off" like in traditional halogen lamps, especially in the cold regions further away from the light sources. It's really common for countries in South America that have humid environments but get a little chilly in the winter. That's why there are desiccant packs now; changing them should be a normal service procedure, like changing cabin filters.

you normally can see the impact - I think I have a video.... let me search

 

[D.J.]

you normally can see the impact - I think I have a video.... let me search

Can see the struggling right side light. Left side no apparent issue

The right side was unable to complete the startup check - cause the desiccant had swelled causing interference

https://imgur.com/a/121gBBd

 

[ldusseau]

Can see the struggling right side light. Left side no apparent issue

The right side was unable to complete the startup check - cause the desiccant had swelled causing interference

https://imgur.com/a/121gBBd

Great video. I haven't started it in the dark yet but I will check.

I also ordered two new brackets and desiccant packs from the dealership. I'm keeping my fingers crossed that new service parts will fix it. If not, well, $$$$$.

 

[D.J.]

Great video. I haven't started it in the dark yet but I will check.

I also ordered two new brackets and desiccant packs from the dealership. I'm keeping my fingers crossed that new service parts will fix it. If not, well, $$$$$.

Please share your findings/observations, after you start in the dark. I am curious.

 

[ldusseau]

I am now too!

 

[ldusseau]

I tried it out this morning. It was below freezing and the light came on right away. It wasn't 100% dark but I found a spot where I could easily see the headlamp reflection. It looks like the right lamp is a little behind the left, but I had to go through the sequence a couple of times to see it because it was very slight. I'm glad I ordered two of everything though (desiccant bags, new retainers and access door clips) because if one is bad the other one can't be far behind.

 

[D.J.]

I tried it out this morning. It was below freezing and the light came on right away. It wasn't 100% dark but I found a spot where I could easily see the headlamp reflection. It looks like the right lamp is a little behind the left, but I had to go through the sequence a couple of times to see it because it was very slight. I'm glad I ordered two of everything though (desiccant bags, new retainers and access door clips) because if one is bad the other one can't be far behind.

I believe the right side causes interference - where as the left side fails the same way - but does not cause the interference, so no practical mechanical issue on the left side.

I would of course replace both if you are doing any

 

[ldusseau]

Your comment is interesting because the headlamp housings "should" be mirror images. I say should because the package space in new cars is so tight there may be components behind the RH lamp that are not present behind the LH. However with the design change of the service parts, that indicates there was a tacit admission of an "oops" in the production design lamp. Something that should have been in a DFMEA and picked up in DV or PV testing. It's a good lesson learned for any headlamp engineer; make sure there is space in front of the desiccant holder so that when it swells it doesn't bind on anything.

 

[D.J.]

Your comment is interesting because the headlamp housings "should" be mirror images. I say should because the package space in new cars is so tight there may be components behind the RH lamp that are not present behind the LH. However with the design change of the service parts, that indicates there was a tacit admission of an "oops" in the production design lamp. Something that should have been in a DFMEA and picked up in DV or PV testing. It's a good lesson learned for any headlamp engineer; make sure there is space in front of the desiccant holder so that when it swells it doesn't bind on anything.

yeah - thus far I have only read about right side failures.... not sure why, since they should be identical. I have not yet inspected, perhaps they are different LEFT VS RIGHT side?

Or perhaps it is just random chance, mostly right side failing first

 

[ldusseau]

It could be that the RH projector has to move just a little further to align the "notches" that you see in the headlamp pattern. The notches were a product of OEM's attempt to miss one test point in the headlamp pattern, the one that causes the most glare for oncoming traffic. IIHS (Insurance Institute for Highway Safety) was mostly behind the push for better performing headlamps but took their quest too far. OEM's decided to "ditch the notch" but many cars still have them. This is why you see many truck headlamps mounted lower on the vehicle, separate from the DRL. Consumers were complaining about glare from LED lamps, especially from light trucks and SUVs.

 

[Xizor]

Where do you all get the new parts? I tried entering the part numbers from the TSB and the various Kia parts sites I've tried redirect to the old parts.

EDIT: Nevermind. It appears kiapartsnow.com has the right parts.

 

[Nedstand]

Hi all!

Here's a follow up to my May 2023 posts where the dealer replaced the right side headlight, but did not even check the driver side desiccant pack, so I replaced it.

So, just 7 months later I checked both sides, and both desiccant packs are hard as rock. The right side had expanded enough to twist the bracket out of shape so I replaced that with a spare I ordered back in May. That one had the bracket installed with the prongs facing inward (toward the wheel well). The bracket with the prongs facing outward did not have to be replaced.

So, I'm going to order some more desiccant packs and plan to inspect every 6-12 months, and replace if needed.