As above. Not sure I agree with the ball bearing issue but I can't say I'm surprised. Unlensed HID headlights are just pure stupidity on both sides: the driver has loads of scattered light so it's brighter but could be much better focussed and more effective - and the oncoming drivers are blinded, putting not only themselves at risk but the idiot with the unlensed HIDs at risk of a collision as well.
There's no better way to put that: HID globes in halogen reflectors just cause light at far too high a frequency to scatter everywhere. It's like asking all the other drivers to watch someone arc welding. If you're not happy to watch arc welding unshielded yourself, don't ask others to do it.
Now, if you want brighter lights - and I can understand that with the D40 barely holding a candle to ... a candle ... then there are alternatives.
Supercheap auto (other places will also stock these) have a range of headlight globes that improve the standard headlights of the D40.
The
Philips X-tremeVision provides a claimed 130% extra light and is currently on special for $89.99 a pair. I haven't tried them myself, but others have reported a significant improvement with these globes.
The
Narva Plus 120 at $82.85 a pair provides a claimed 120% extra light and I have used these (in my wife's car). Not sure that it's 120% more - it might be in the order of 30-40% based on a perceptual gauge, rather than a lux meter - but they definitely made a difference.
That's my pick of the 60/55W range. There are higher wattage globes which will put out more light. From the $13.95-per-globe
SCA Halogen 100/90W to the IPF Fat Boys (about $180 a pair from ARB and possibly others). I've used the Fat Boys myself. Yes they are brighter, but they also seemed more fragile. My original (factory) globes are STILL going strong. I am not sure I like the extra power drawn through the thin headlight wires though, and another user of this forum came up with the solution to fix this too.
You can buy a H4 extension on eBay (
here's one example) and get to work on it. You'll need extra wiring and some fuse holders plus a pair of relays. Call the female plug the output and the male plug the input. There are three wires - earth, low and high beam.
Connect pins 86 of the two relays to earth (which can be provided directly from the battery, ignoring the earth provided in the harness). Also connect this earth to the earth of the H4 socket.
Connect pin 85 to either low or high beam lines on the input plug (it doesn't matter as long as the output of this relay goes to the same position on the plug that goes in the headlight).
Connect pin 87 of the relay to the same position on the female output plug.
Repeat the previous two steps for the other power wire.
Now, grab that fuse and attach it to the battery. Run a decent sized cable towards the headlight and attach it to pin 30 of BOTH relays.
Repeat everything for the other headlight.
What you've done is increase the amount of power (voltage) available at both headlights. The headlight wiring is far to small and there are significant losses especially at higher loads (so if you DO choose the 100/90W globes it'll be even worse). This circuit fixes that.
Doing this WILL give you more light - legally. The halogen filaments are in the correct location as Tappet has described so that the light is actually directed where it's supposed to go rather than being scattered.
6000K is also (as Tappet points out) far too blue. It's actually illegal for its colour - I think the limit is 4300K. 6000K is well beyond that and easy to pick. Personally I can't wait for the police to do a blitz on stupidly bright or blue headlights. There are a few idiots in the Hunter with lights like that now and they're just so annoying. One idiot in a Hilux travels to work in the opposite direction to me each morning and one day I'm going to chase him down and get his number plate so I can report him.