From another thread looks like its known design fault not me or just bad luck,
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
Blown headlamp bulbs on one or both headlamps
Kuga 2008.5 (02/2008–) - vehicles with conventional headlamps
Build Date: Up to 21.10.2010
Build Code: Up to AR
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
• 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
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
Description Finis Code Quantity
1 715 479
Headlamp bulb H7
Operation Description Operation No. / Time
Resistor Wire Install On Both Headlamps - Fiesta 2008.75
Includes: Headlamp Assembly (Left-Hand Side) Remove And Install
Resistor Wire Install On Both Headlamps - Kuga 2008.5
Includes: Loosen The Headlamp Assembly On Both Sides
ACES Condition Code:
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.