For the last year or so I've noticed the dip beam on my 2012 Focus (Titanium X with xenons) seemed to get really quite dim, to the point where it felt like it got quite hard to see without the full beams on. Thought I'd try replacing the bulbs (went with OE replacement Osram ones) and they made an almost negligable difference. From there I've tried replacing the ballasts on both headlamp units and again, it feels like a tiny difference.

Anyone have any experience with this issue? The auto levelling still looks to work and I've tried manually tweaking them every so slightly, so I don't think the issue is that they're pointed at the floor. When I flip to full beam, everything seems fine. Checked the fuses and they seem fine (appreciate they probably wouldn't work at all if that were the issue).

Thanks!

The problem is that the chrome reflector inside the projector has become corroded/dull. 



The amount of light that is bundled and projected into the lens is now reduced drastically. Replacing the HID bulb or ballast has little to no effect.

This is a well-known problem of older HID headlights. The Focus MK3 HID headlights are not particularly known for their decent light output. When the reflectors become corroded/dull, the light output becomes even worse.


The only way to fix this is by replacing the projectors. Aftermarket replacement projectors are available from various suppliers. However, these headlights are designed in such a way that the projectors cannot be removed. To be able to replace the projectors the headlights need to be fully disassembled. This means that the front plastic lens has to be separated from the headlight housing. The Focus MK3 has headlights that are sealed with Permaseal. This makes removal of the lens without causing permanent damage extremely difficult.


So bottomline is that you either have to replace the complete headlights or disassemble the headlights and replace the projectors.

5 hours ago, JW1982 said:

The problem is that the chrome reflector inside the projector has become corroded/dull. 



The amount of light that is bundled and projected into the lens is now reduced drastically. Replacing the HID bulb or ballast has little to no effect.

This is a well-known problem of older HID headlights. The Focus MK3 HID headlights are not particularly known for their decent light output. When the reflectors become corroded/dull, the light output becomes even worse.


The only way to fix this is by replacing the projectors. Aftermarket replacement projectors are available from various suppliers. However, these headlights are designed in such a way that the projectors cannot be removed. To be able to replace the projectors the headlights need to be fully disassembled. This means that the front plastic lens has to be separated from the headlight housing. The Focus MK3 has headlights that are sealed with Permaseal. This makes removal of the lens without causing permanent damage extremely difficult.


So bottomline is that you either have to replace the complete headlights or disassemble the headlights and replace the projectors.

Did wonder if that might be the case after seeing your replies on some other posts, hmmm.

Do you know if the halogen units suffered the same issue? And I guess if not, I wonder if it's possible to convert it back to a "normal" unit?

It is basically a matter of poor-quality projectors. On the other hand you cannot really complain about quality after 13 Years.

The standard halogen headlights do not suffer from this problem. The Focus MK3 halogen headlights however do also not have a very high light output. I drive a Focus MK3 with halogen headlights regularly and still notice the poor lights every time I drive that car.


It is possible to convert a HID equipped Focus MK3 to the standard halogen lights. This however requires a few modifications to the wiring, disconnecting the HCM (Headlight Control Module), installation of a manual height adjustment light switch and a bit of programming.

Considering the fact that the light output of standard halogen headlights will probably be just as poor as your current headlights it is probably not worth the effort.

 

I had exactly the same symptoms with mk2.5 Xenon’s just didn’t go as far as changing the ballasts. Got away with hi-beam as there is a supplementary bulb for this but low beam was terrible. 
 

There were some videos on an RS forum detailing how to cut into the casing of the lamp then heat it up to bend it out of the way for fitting a replacement reflector kit. Needed heating again and sealing it up afterwards etc but I opted to get a set of replacement lamps from Autodoc

I also bought a new pair for my ST.  I did know of a man that had done a pair - said he would never do it again!

20 minutes ago, Paulkp said:

I also bought a new pair for my ST.  I did know of a man that had done a pair - said he would never do it again!

I'd love to but the prices I'm seeing for new MK3 ones are eye watering, probably the value of the car haha

For LHD there are quite a few aftermarket alternatives (pattern parts) For the original HID headlights these days. Prices start at about €500,- a pair which is quite a good price.

These come without any bulbs and ballasts. Apart from that these lights are plug and play.


There may be manufacturers that also manufacture RHD versions.

is it something like this what you guys bought?

https://www.ebay.co.uk/itm/127198182905?

i find that sometimes mine isnt bright enough too.

 

 

Not applicable for a MKIII, but these are what I bought from Autodoc for a 2008 ST3.....

You have ordered the following items

Headlight £398.95 Article №: 1LL 354 807-071 incl. 20% VAT Quantity : 1 £398.95

Headlight £398.95 Article №: 1LL 354 807-081 incl. 20% VAT Quantity : 1 £398.95

Order subtotal : £797.90

Delivery : £0.00

Safe order: £3.95

Order total: £801.85

incl. 20% VAT Delivery : standard shipping

Delivery only on working days.

 

"eye watering........."

I got a discount from Autodoc after I signed up for their App