QUOTE(Gunn1 @ Jan 6 2017, 03:21 PM)
Could it be there is a stray voltage surge that pops the bulb?
Most likely this is the case although it's likely not so stray. My buddy had I think a Suburban that always blew out the one front driving light.
The surge could be when you turn OFF the lights as the inductance of the wiring and load (headlights) can cause an undershoot.
When you turn on or turn off the lights, a step function of voltage is applied/removed to/from the wiring. The inductance of the wiring (all wires have inductance) causes an overshoot.
Below is Pulse 1 from ISO 7637-2 automotive standard for removal of power from a circuit with an inductive load like headlights. An inductive load resists a change in current. When current is removed immediately, the current in the load powers the circuit.
In Figure 5 below, Pulse 1 from ISO 7637-2 causes the negative going overshoot. UA is battery voltage of nominal 12-15V. The undershoot US is upwards of 100V.
Solution would be to check all wiring and your light switch. If your light switch is making/breaking with some jitter (on-off-on-off) as you move it, it could cause multiple Pulses 1 as shown below.
In ISO 7637-2, Pulse 1 should be applied 5000 times to verify that the unit under test passes the standard.