Went to replace the lamp with a brand new one, but the housing has melted. When I installed the new lamp, it would turn green, blink a few times and then turn red and blink. It would eventually turn off. I'm assuming the fan stopped working at some point causing the lamp to melt the housing. What can I do to repair it?

SOURCE: Power LED blinks red

it is a bad fan. it also could be a power supply. Quite often the real problem is dirt clogging up the fan(s) to the point that they need to be replaced. Operation of the set in a dirty environment is not a good idea

SOURCE: melted plastic where the lamp is positioned

I would suggest to call Sony if you have a safety concern about your TV. A fire hazzard is unlike because most if not all the electronics components or plastics used on TVs have a flame retardant that It will not burst into a flame.
Good Luck.

SOURCE: Sony KDF-42WE655, lamp burrning out and melting.

I am having the same problem with my kdf42we655 model. except I also have the blue/pink blobs all over the screen. Sony came last week to evaluate and were pointing to the amount of dust in the set... What a crock... Dont know what theylle do yet but I am ready to get a lawyer and fight this. They know there is a problem and dont want to back it up... Ill never buy Sony again.. And btw. if your buying a new tv and you a sony fan,. look at samsung.. They are building the new lcd screens for Sony...At least Samsung stand behind there product and costs a lot less than paying for the Sony name..

SOURCE: Sony KDF-46E2000 - Screen Goes Blank

You definitely have a bad lamp. Sony rates the lamp life at between 4000 and 8000 hours. There are 3 things that effect the lamp life, listed in order of importance:
1) number of times the lamp is turned on and off. Every time the lamp is first fired, it takes life off the lamp. Customers I see that turn the TV on in the morning, leave it on all day and then turn it off on the evening can get up to 12000 lamp hours
2) ventilation. Be sure you have at least 6 inches of open space all the way around the set and that the vents are clear of dust and debris.
3) power. If the power is interrupted when the set is on, there cannot be a proper cool down cycle. The fans will run after you turn the set off to properly cool it down, if the power is lost this cannot happen. If your power is unreliable, buy a small UPS to let the set finish a cool down cycle

Occasionally a lamp will faill before the average lamp time due to being defective. from your purchase date it sounds like you got about average lamp time. Be sure to purchase AN ORIGINAL SONY LAMP as a replacement, becuase the aftermarket lamps are bad news, Be sure to rate this solution. Thanks!

SOURCE: Projection lamp casing melted.

This will be covered covered under warranty by Sony. If you will call 800-282-2848 you can locate a Sony authorized servicer that should be able to repair this at n/c.

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