I received my 2nd set of PWM today. When I installed the first set for the headlights, they worked great! No issues, everything plug and play. The PWM module does get hot! Hot enough to where you wont want to hold onto it. Just a fair warning. It gets hot after about 5-10 mins. Now I'm curious about what if you have a road trip that requires night driving. Say ~8-10 hour torture test would be a good idea, to see just how hot and the durability.
A slight background. I already have the Xtreme kit for my headlights for the past 2 years. I ordered 2 sets of the PWM and another Xtreme kit for my foglights. Anyways, had to hold off on installing my foglight set until today, since I was missing my 2nd pair of PWN. I pre-installed the ballasts. The Xtreme ballast from my passenger side fell off from it's original location. I figured, since I use the headlights the most, I'll install the brand new ballasts for the headlights instead and transfers the older ballasts to fog duty. Like I said, the passenger side fell off, so that was easy to swap. The driver side was still secure. I didn't want to ruin the hold, so I just left the driver side as the original.
So I installed the mis-matched ballasts in a location, where I'll be able to reach the plugs from the wheel well. I didn't want to remove the bumpers when the 2nd pair of PWN came in.
So onto the foglight install. The PWM connector, does not match the factory H11 connector. On my driver side, I must have busted one of the tabs, so I was able to jam it in far enough and hold in place. I tested the foglight and it turns on! Woot, looking great. I do not like the idea of how unsecure the connection is though, so I'm going to wrap some electrical tape around it once I get everything done.
Now I go to the passenger side to do the install. Get everything plugged in and turn on the lights..... uhhh nothing. Uh oh. I double check all the connections and they are all tight, except for the factory harness to PWM. It didn't look at close at the other side, since both tabs are intact here. I'm thinking well, what can I do. I look at my spare harness with the Xtreme kit. I guess I'll remove one of the plugs from it and use it on my factory harness. I didn't like this idea, but this was what I had on hand to make the connection fit better. I removed the pins and changed the plugs. Now I have a tight connection.
Turn on lights again and still no light for passenger side. Ugh, wtf. Maybe bad bulb? I unplug each connection and look at the pins and such. I found corrosion in the plug coming off from the ballast. Hmmm, that is probably the culprit. I cleaned what I could with a brush in that confined space. Looked good enough and test lights again. Still nothing. I'm thinking probably bad ballast, PWM, and/or bulb. Now I remember I have an old Morimoto ballast from a couple of years ago. This was their bad batch that were having issues with cold temps. I figure, what the hell.
Plugs right up and it works! So I can confirm the PWM works with Morimoto 35w ballasts. I unplug the Morimoto and plug the old Xtreme ballast again and still doesn't work. Isolated it to this ballast. It died somehow since when I uninstalled it from about 2 weeks ago. Was working perfectly fine. Maybe the corrosion did it's damage. Don't know. As of right now, I'm just going to leave the Morimoto in place. I'll place an order for a 3rd Xtreme kit when they have another sale again. I just hate to have to take the bumper apart again. When I do, I'll have to recheck every connection and maybe place some dielectric grease to prevent corrosion.
After cleaning up inside and looking over the remaining spare parts and such, I notice on the harness I separated from the HID bulb harness. It has a plug that fits the OEM plug! I didn't use this harness, since I didn't need a pass-through connection like with the headlights. I just cut the rubber grommet and easily ripped out the wires.
So I removed the plugs from this spare harness and removed the little rubber gaskets too. Whenever I do replace the Morimoto, I'll make sure to change the ends on the PWM so it has a better connection.
Here's the factory connection for the foglights and the end of the PWM that it's suppose to connect into.
Corrosion on my old Xtreme ballast
The H11 bulb that was I was using. The OEM connector that I removed on my passenger side. 2 plugs from the harness I salvaged that I will put on the PWM the next time. And the little rubber gaskets for the wires.