Headlight Malfunction - broken wires

[Andy Mann]

I bought a focus st3 2016 from a VW garage (ironically an event that seem to blow Ford and VWs mind and not fit in with any of both manufacturers policies), within six months i got a “headlight malfunction service warning light on the dash) I took it to ford (after 50 phone calls between the two) turns out one of the wires that go into the headlight itself has snapped) ford say they can’t repair only replace - it will cost £1200 For 1 light! The mechanic said it’s a unit failure- no impact signs or penetration of unit.
VW said that it is not covered as wiring is exempt from their warranty leaving me helpless, stuck between the two and with a 1200 slacker bill to pay - does anyone have any ideas??

[Luke4efc]

I mean you could just find the broken wire and crimp it back together if that's all they're saying it is. Otherwise take it somewhere other than a main dealer so you don't get shafted on prices.

[Andy Mann]

HI Luke, yes I will do, thanks 😋

[Reddamper]

I have had the same issue twice. Got the same runaround from ford dealer. Have extended all 3 wires and have connected them back into the white connector block.
Works fine now.

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[RickR]

Do you think your repair technique would work on the smaller connector block a little further in?

Ford are asking for £960 to replace the unit but I’ve just discovered one of the wires snapped off the small block. 
Looks very fiddly!!

[Reddamper]

Do you think your repair technique would work on the smaller connector block a little further in?
Ford are asking for £960 to replace the unit but I’ve just discovered one of the wires snapped off the small block. 
Looks very fiddly!!

Yes it is fiddly but worth the effort. Are you referring to the white connector block? If so, I extended all 3 wires, didn't solder them either just forced them into the pin housing. I might have some photos.


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[Reddamper]

The wire which sheered off the connector block.

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[Mc Bam]

I had the issue with the drivers light not resetting when cornering, it only reset with either stopping or switching off the ignition. So with any car fault a Internet a search brought me here. So Light out, had a check, couldn't see any broken wires. Still puzzled with it, another search took me to how to diagnose what was faulty by swapping parts between headlights, either the led, ballast, wire harness could be at fault. I knew the Led was fine so I swapped the ballasts around... Bingo! It resets when cornering! I might be early in posting that it works for my car as I only tried it yesterday. It's worth a try if your headlights like mine and no obvious visual fault in the unit. 

[nicam49]

On 11/28/2019 at 9:22 PM, RickR said:

Do you think your repair technique would work on the smaller connector block a little further in?

Ford are asking for £960 to replace the unit but I’ve just discovered one of the wires snapped off the small block. 
Looks very fiddly!!

I just despair that they can't get an auto electrician (surely they have one?) to REPAIR the broken wire? Have we now lost the ability to fix even simple problems? 

[RickR]

Thanks for the help/suggestions. 
 

Unfortunately it wasn’t the easy to reach white connector where the break was. There’s another connector block on the circuit board which is where my offender was. Too scared to take a soldering iron near it I used some “Silver Epoxy”, a conductive epoxy glue that I ordered from the US. Expensive stuff (£50 for 13g) but it did the job, £910 saved!!

[Fordyboy41]

Yes I have the same problem the smaller connecter block one on the wires have snapped out...I've tryed twice to get wire back in its so fiddly dont seem to want to go in 

[marcb]

For anyone coming across, I had the same issue. Garage quoted me near £1300 for a replacement light.

Found this website https://adaptivefix.com/ and ordered a replacement wire for £10 which solved my problem