Thanks Tom. I watched this video, and others, a couple times along with some written tutorials before I started the job.

I paid special attention to make double sure the tab was seated in the housing at 6 oclock for the low beam unit. The connector prongs for the plug are at 6 ocklock and 12 oclock which verifies the bulb is in their correctly.

Something else must be going on in there and I'll have to figure it out. Now, one thing I noticed while fiddling with this is that the whole low beam unit wiggles a little bit when I was working with the bulb. Not the whole low/high beam assembly, just the big plastic silver round housing. Is that unit supposed to be rock solid?