Headlights Blowing - How to fit resistor wire

[jimb85]

Hi,
My headlight bulbs keep blowing. Looks as if its a common problem with power surging and thus blowing the bulbs. I have identified the parts I need (resisitor wire), however not too sure on how to fit these? Doesn't sound a big job - just unsure on how to do this.
Has anyone had to do the same and would like to share how they did it? Photos would be great
Thanks for your help.

[Neoyami25]

I'm having the same issue I have gone through 3 bulbs in 4 months and it blows when lights activate please update when you have fixed thank you

[jimb85]

Hi, looking on forums Ford issued a TSB on this, so the below will help to identify the problem. My question to the forum is how do I fit the resistor wire? Surely others have had to do this as it seems to be a common fault on our model:

This bulletin represents technical service information only.
Without exception all gratis repairs and replacements are subject to the
individual warranty and policy procedures of the supervisory Ford Company. The
illustrations, technical information, data and descriptive text in this issue,
to the best of our knowledge, were correct at the time of
publication.





Subject/Concern:
Blown headlamp bulbs on one or both headlamps

Model:


Fiesta 2008.75 (07/2008–)

Build Date: 21.07.2008-23.09.2009
Build Code: 8D-9C
Assembly Plant: Cologne

Fiesta 2008.75 (07/2008–)

Build Date: 12.01.2009-23.09.2009
Build Code: 9J-9C
Assembly Plant: Valencia

Kuga 2008.5 (02/2008–) - vehicles with conventional headlamps
only

Build Date: Up to 21.10.2010
Build Code: Up to AR
Assembly Plant:
Saarlouis




Summary


Should a customer express concern about repeated, blown headlamp bulbs on one
or both headlamps, the probable cause is a voltage spike in the electrical
vehicle system.


• NOTE: Fiesta 2008.75: It is not required to remove the headlamp
assembly on the right-hand side.


• NOTE: Kuga 2008.5: It is not required to remove the headlamp
assemblies completely.


To rectify this concern, an resistor wire should be installed on both
headlamps between the current electrical socket and the headlamp bulb H7.


Labor Times published in this TSB are available from 25.10.2010 onwards.
Please refresh your Labor Master file at that day to receive the new data in
your Dealer Management System. Please contact your internal system
administrator.








Parts Required

Description
Finis Code
Quantity

Resistor wire
1 715 479
2

Headlamp bulb H7
see FordEcat
-



Labor Time

Operation Description
Operation No. / Time

Resistor Wire Install On Both Headlamps - Fiesta 2008.75

Includes: Headlamp Assembly (Left-Hand Side) Remove And Install
710041C65

Resistor Wire Install On Both Headlamps - Kuga 2008.5

Includes: Loosen The Headlamp Assembly On Both Sides
710041C65



Repair/Claim Coding

Causal Part:
36319

ACES Condition Code:
42

OASIS
201200, 203200
Production Action
The resistor wire between the current electrical socket and the headlamp bulb
H7 has been installed in Cologne/Valencia production since 24.09.2009 (build
code 9C) and will be installed in Saarlouis production from 22.10.2010 (build
code AR) onwards.


Service Instruction
See Summary.


Resistor Wire - Install (On Both Headlamps)

[jimb85]

Have bought the parts, struggling to see how the connectors (x2 spade style) connect to the car/power adaptor - they look too big to go in to the adaptor!!

[jimb85]

Ok, so I have managed to fit the resisitor wires - with the help from Shabazmo. It really is simple when you know what to do!!
So...

1. Take the headlight unit out as you would to change the bulbs.
2. Take the H7 bulb out.
3. Take off the metal clip which is used to hand screw the H7 bulb back in place.
4. Connect the 2 spade connectors at the end of the resistor wire in to where the bulb was (1 spade in to each of the connections where the 2 prongs from the H7 connected).
5. Add the metal clip to the end of the new resistor wire connector. It should now look exactly the same as the original connector.
6. Put bulb in to the new connector (end of resistor wire).
7. Hand screw back in to headlight unit.
8. Re-assemble headlight unit to car.

Also I decided to change the bulbs themselves. I have gone for the Philips X-Treme Vision (+100%). These are fantastic, so much more visibility in the dark, not sure its the quoted 100%, but a noticable and marked improvement on a standard H7. Worth the £20 that Amazon sell them for.

[Fussums]

Hi Jimb85,

I am aware you posted your solution many moons ago, however im experiencing this problem and would really like to fix it. ive made an account specifically just to post this!
what wire did you use and if there's any chance of a link that would be brilliant.

Cheers