Last night both headlights died on my wife while I was at work. Due to previous problems with one light staying on she knew where the fuse was for the relay harness, she checked the fuse and it was good. This morning I started troubleshooting, and nothing helped except for reseating the relay harness's plug (at the relay box). When I did that, both lights would work, but one would fade in, fade out, flicker, then turn off. I called TRS and they swore up and down it was the ballast. I swapped it all around and the problem did follow the ballast. Also during my testing (during the musical ballasts and reassembly) the relay behaved exactly as they should. I mounted the relay box in a different location just to help keep it from the elements, and called it good (with only one light, replacement ballast is enroute). I went to work, called the wife on my break to check up on the lights and she said that the passenger side wouldn't turn off and she had to pull the fuse (driver side is without ballast). I called her again later on in my day after she had gotten home and she said everything behaved like it should, turning on and off as usual. I'm thinking there is a sticky relay in there somewhere.
