Unfortunately, I did not think to get more pictures of the removal process. I did try and grab more pics of the install process.
Disclaimer: HID lights are HIGH VOLTAGE and can be very dangerous. Extreme caution should be taken whenever working around these systems! It is recommened that a trained professional handle repairs of this nature. I am not responsible for any bodily harm or damage to property should anyone attempt this repair themselves.
Part II - Installing the new ballast
The aftermarket ballast I used was from Xetronic:
Xetronic Ballast Module (Single) for Factory/OEM HID Xenon Lights (D2S/D2R Compatible)
The real trick in installing the aftermarket solution was to prepare the new ballast by splicing in the power connector from the old ballast and then finding a place to mount it to the car since the universal bracket on the new ballast did not line up with the factory mounts underneath the headlight.
Therefore, I first clipped off the power connector from the old ballast and used butt connectors to wire up the power and ground leads on the new ballast. After a bunch of research, it seems water/moisture are ballast killers, therefore, I also used heatshrink tubing and electrical tape to keep the wires together and keep moisture out (see ballast connector 2.jpg in previous post for image).
Pic 1 - Here you can see I cut off the connector from the old factory ballst.
Pic 2 - Here is the connector spliced into the new ballast before wrapping it in electrical tape. See pic attached in post 1 for the completed splicing and wrap.
With the new ballast prepped, I had to find a place to mount it. As luck would have it, it fit right above the plenum box. I tucked the 2 flanges (mounting holes) under the steel bracket and then zip tied front mounting hole to the steel hinge on the plenum box. This held it securely in place. Note, this is for the driver side HID system, I have not looked at the passenger side to see where a replacement ballast might fit. Should anyone attempt to replace the passenger side, it would be great to add an addendum to this thread with details on how the passenger side works out.
Pic 3 - Here the new ballast is sitting on top of the plenum box with the flanges tucked under the steel bracket and the front mounting hole zip tied to the hinge. Zip tie is black so it is a little hard to see.
Pic 4 - Another angle so you can see how it fits.
I was then able to feed the socket connector up through the bottom of the HL just as it was with the factory ballast and install the bulb and use the retaining clip to hold it in place. I also was able to route the power connector back up the side of the headlight just as it was with the old ballast. Note, I also wrapped the connector to the ballast with electrical tape to help keep out moisture.
I then connected back up the various lights and slid the HL back in place and secure the top 2 bolts.
Pic 6 - Here you can see with the ballast installed, the light back in and the bracket in place, there is plenty of room.
You can see that the mounting location for the new ballast did not interferre with the HL nor the bracket. I then installed the HL bracket to complete the install process of the HL and ballast.
The remaining steps were to put the bumper back on which is the reverse of the removal process.
Overall, the job was fairly easy and only took about an hour start to finish. The new ballast does make a hum for the first 20 seconds or so while it warms up and ignites the bulb. I also noticed the color of the light was slightly different than the OEM ballast. However, I think this is due to I grabbed the wrong bulb when I installed it. Note, during my original troubleshooting of the headlight, I purchased a replacement bulb to see if that was the problem. I am guessing that the replacement bulb was not quite the same color as the factory bulb.
Well, that is how I solved my HID light issue and saved over $300 in the process.