Did a search on headlight housing bulb replacements. Is there a cure for the melting issue?
 

And consequent brand/part# bulbs that work without melting the housings?

And thanks to Sparkhill for all of the writeups.

this may not be what you want but LED cluster bulbs will generate much less heat,

sparkhill seems to know the most about this issue, i'd just email him directly.
 

unless you already have.

Not really...
 

It seems that <b>all</b> of the coated bulbs have a tendency to melt the housing. Silver is hotter than the blue, but they will all melt the housing. Some have even completely melted the bulb sockets too. There are LED's available - I have had a set sitting on my desk for months but have never installed them because I know I will not like the way they look although I do think they will work without throwing codes. Way back in the beginning, one person here installed Angel Eyes and that, along with clear corners, would be the way to go.

If you have a melting issue, your dealer can probably help you out. Some dealers have been very good about correcting the problems. Others... not so much. Hoen worked with the RS4 community to come up with the LED's they currently sell.

If you have any questions about the above, let me know.<ul><li><a href="http://www.hoen-usa.com/">http://www.hoen-usa.com/</a</li></ul>

So to be safe, at this point, I could change my fog light bulbs to Piaa's or Silverstars?
 

And not worry too much about the other bulbs in the headlight housings?

You are probably fine changing the fogs
 

The melting issues occurred when people changed the DRL's in the headlamp housing. If you do change the fogs, just keep an eye on them to make sure they were not getting too hot. I have had the Hoens since summer 2006 and have experienced no problems although I do not drive with the fogs on all the time.<ul><li><a href="http://webpages.charter.net/parkhill/RS4/DIY/FogLightBulbChange.pdf">Fog Light Write-Up</a></li></ul>

But to avoid a bulb failure warning, you'll need to add a resistor ... which generates as much heat

The LED bulb cluster lights (from Hoen) do NOT fit through the housing openning
 

I have a set sitting at home and am unable to install them for that very reason.. they don't fit. I am thinking about filing down the 'side' LED's to get it slightly smaller, and see if the setup will work.

I melted my housing and got one bulb out, but the other is stuck in there. I have to work out a way to generate some heat in the housing to try to yank it out but I haven't screwed with it too much yet. The dealer refused to warranty it, of course.