Please have patience and fortitude, my story below will take a minute or two to read. I really need good advice from anyone who has experience of taking on Ford with a technical fault that is clearly a design flaw...
I have arranged replacement tomorrow by my Ford local dealer (from whom I bought the new 58-plate Mk7 Fiesta Titanium 1.6 TDCi) of the latest of several (dipped) headlamp bulbs that have blown since buying the car. Bulbs in both headlamps have gone at different times, each time after only a few months of average UK use.
The last time I did this, after several previous replacements, for some of which I was charged, some kindly not, on dispiritedly taking it in again I was informed (politely as always) that Ford had come up with a 'fix' for the problem, caused as mentioned earlier in this thread, by voltage spikes. I arranged for the kits, consisting of a resistor 'choke' behind each bulb socket, to be fitted (for which again the dealer considerately waived charges, evidently valuing my patronage; the car was by that time out of warranty) simultaneously with the blown bulb, and drove away, hoping not to have to call again, for a reasonable period of time, anyway.
(BTW Although I have personally maintained a wide variety of vehicles for many years, I shied away from trying to replace the bulbs myself after looking at the very cramped space in which to work).
Now it's clear that the 'problem' hasn't been resolved by the 'fix' kit, as another bulb has blown after only a couple of months.
I have asked my dealer for a full list of the service events involving the bulb replacements, and for the fix kit installation, to document the history of this issue. It is clear to me, particularly now that I have learned that some Kuga models also suffer from the problem, that this fault arises from a design flaw in the car's electrical system, or perhaps the control unit. I imagine (but do not know for sure) that the control system software plays a part in the charging and lighting power functions of the car, so it seems logical to suggest that a software patch may be required.
I have no idea how Ford manage these issues, and I am well aware, this being the 6th nearly-new or new Ford that I have owned, that they are very reluctant to admit to faults in their products, so tackling the supplier head-on may be a wearisome and ultimately unproductive process. I hope to enlist my dealer's assistance in doing so, but I have no idea what are the chances of success.
This Fiesta was one of the early ones off the new production line, and it clearly carries at least one teething problem that has not yet been fully resolved - Ford's provision of the fix kit is an indication of their acknowledgement of the existence of the problem.
I want to find a way to stop this senseless waste of time and money, replacing expensive halogen bulbs that should not blow in their short lifetime. I want to find a way to get Ford to admit liability for the design flaw, and provide a proper solution; one that works, permanently.
Any advice that anyone can provide would be greatly welcomed.