Headlight bulbs (stock) actually exploding

[wambus]

My son is driving this truck now, but I am helping him with issues.
He is going through bulbs fast. And he is telling me that they are exploding in the housing.
This vehicle was purchased new by my inlaws and then given to us for my daughter. She later passed it to my son. No modifications whatsoever and no history of this happening before.

What should we be looking for. Note that we are careful not to touch bulb with our fingers when installing.

 

[donalds]

Interesting

 

[wollimann]

Had this exploding behaviour once, not with Ford OEM Bulbs, not while driving, not on both sides.
It was time for our Technical Supervisory Association, changed the headlight bulbs before cause
they were old and lost brightness. Put in expensive H4 Osram Night Breaker with 20% more brightness.
Car was idling on the hoist, then the checker do the O2 test with higher RPM, to get temperature.
After that he do the light test, everything ok and he shut off the engine without shutting off the headlights.
One minute later the new right headlight bulb exploded with a bang.
I am quite sure it was the heat that killed the bulb in relation with the +20% bulbs
(believe they work with less current?) and not a electrical problem.
Headlamp has to come out, broken piece of glas has to come out.
Bad thing now, the reflector has some debris/dust on it and i don't know how to clean it.
Never put in these brighter bulbs again, never had an issue since that.

 

[allmyEXes]

A long time ago, in an old Ford that had an external voltage regulator, apparently it quit regulating properly (increased voltage) and every
bulb in the car that was on, blew. Headlight bulbs, running light bulbs, etc. Check your running voltage to rule out a bad voltage regulator.

 

[410Fortune]

What year is this explorer?
Corrosion on the wiring pins or wiring pigtails to the bulb
Don’t touch the glass part of the bulb the oils from your skin can ruin it use a dry cloth I would check voltages first battery should hold 12.2 or so and while running at warm idle alternator should be at 13.8-14.3v

 

[wambus]

1999 exploder.
Plugs look good. Will have son check harness for issues with the wiring

 

[donalds]

Check for AC voltage when running hot

 

[C420sailor]

Gotta use a good meter though. Apparently low end DVMs won’t pick up the AC voltage from a leaky diode bc of the way they measure AC voltage

 

[J_C]

How often is this happening and in what weather conditions?

Bulbs don't mind AC current, but they do mind a faulty alternator regulator putting too much voltage through them. Even so, I would wonder if you have a leaky headlight housing and water is getting in, then hot bulb plus a water droplet hitting it, will shatter it.

What bulbs specifically? If they're some dodgy LED retrofit bulb, no surprise. If an especially high output incandescent bulb, then for the time being I would get some of the cheaper long life bulbs offered on Rock Auto, and then at least it will mitigate the costs of bulb replacement if not solve it.

I don't think it's a bad electrical connection to the bulb. That can burn bulbs out from constantly letting the filament cool down and heat back up, but shouldn't shatter them, just burn them out.

 

[amj441]

I have had this happen semi-frequently with my explorer (one bulb every 9 months - 1.5 years or so) but they explode and throw glass all over the headlight housing. I have never used anything other than the sylvania stock replacement halogens. I dont touch the bulbs as I know the oils on your hands can cause them to break and they still explode. My old housings were this was happening were oem and were starting to get a little moisture in the left headlight, which I believed may be causing them to explode, (like thermal shock when I hit a bump and they get wet). but it started happening to the right side as well even though moisture was not getting in. All of my connectors dont show signs of corrosion, and the contacts are not burnt (unlike my taillights)

I have since replaced the housings and alternator but have been having too many engine issues to be using the car with any real consistency to see if this resolved my issue. I am curious to see where this one goes.