Hi all,

I am continuing to get problems with my Fiesta 1.4 tdci. I have another thread for the ABS issue, but now I'm having trouble with the headlight dip and main beam not working properly.
SIde lights and front fogs work fine.

I thought the bulbs had gone, so just changed the passenger side first.
Bulb looked OK, but changed it anyway.
When I put the cluster back in, both sides were on, but extremely dim. Then after a few seconds, they died out, as if no power. Side lights and fogs still on.
I took out the passenger headlight cluster again and noticed that the plug which attaches to the bulb has melted and is slightly deformed (I'll try to add pictures now).

I can assume that this may be causing a connection problem and is causing insufficient power to be sent to the passenger H4 bulb?
Would this also affect the drivers bulb power?

I then changed the drivers side. The bulb had gone (which is strange, as it was working dimly just a minute ago).
The plug for the H4 is fine on this side.
Replaced everything and the drivers light seemed to be working fine, with the passenger side still dim.
The next thing I knew, a few seconds later, the both were off again.

Removed the drivers cluster again to check that the bulb hadn't blown again. It was fine.

Decided to check all the fuses. All seemed fine, although one or two were the wrong ampage (don't have spares to hand).
When I was pulling them out I heard a quiet ticking, which sounded like a connection being made (didn't take note which fuse). When I looked up, the dash lights were on for the dip and main beam. Looked at them and they were working on the drivers side, yet still dim on the passenger.
Turned them off and they wouldn't come back on. This has helped me notice that the dash lights are not illuminating now for the dip or main beam.

I have now removed the passenger cluster again to try and clean up the connections and make the wiring a bit better.



ANyone got any ideas what my problem is please?
Can someone please tell me what the plug/blobk thing is called that plugs into the headlight bulb please, so I can order another one?
If this is an electrical issue, could this be causing my limp mode, or the ABS or glow plug fault codes?

Thanks in advance 🙂

Edited May 23, 20215 yr by jackrmee
Added photos

On 5/23/2021 at 10:33 AM, jackrmee said:

Can someone please tell me what the plug/block thing is called that plugs into the headlight bulb please, so I can order another one?

It's called a headlight plug... 

What's the top wire with the clean copper showing?  Doesn't look right and may be the cause of the overheating.  A loose terminal is the other reason for that sort of issue.

On 6/5/2021 at 2:09 PM, TomsFocus said:

It's called a headlight plug... 

What's the top wire with the clean copper showing?  Doesn't look right and may be the cause of the overheating.  A loose terminal is the other reason for that sort of issue.

Thank you mate.

 

I’ll order a new plug.

Does this seem the right one? 
https://www.ebay.co.uk/itm/300615573892

 

thanks again.

6 minutes ago, jackrmee said:

Thank you mate.

 

I’ll order a new plug.

Does this seem the right one? 
https://www.ebay.co.uk/itm/300615573892

 

thanks again.

That does look right, yeah.  Would be best to solder it in but you can probably get away with crimps or choc blocks if you don't have a soldering iron.