this is a known problem, it requires a resistor wire to we put in, as this is to to voltage surges, please see the TSB from ford below
© Ford Motor Company
All rights reserved.
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
publication.
Subject/Concern:
Blown headlamp bulbs on one or both headlamps
Model:
Fiesta 2008.75 (07/2008–)
Build Date: 21.07.2008-23.09.2009
Build Code: 8D-9C
Assembly Plant: Cologne
Fiesta 2008.75 (07/2008–)
Build Date: 12.01.2009-23.09.2009
Build Code: 9J-9C
Assembly Plant: Valencia
Kuga 2008.5 (02/2008–) - vehicles with conventional headlamps
only
Build Date: Up to 21.10.2010
Build Code: Up to AR
Assembly Plant:
Saarlouis
Summary
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
vehicle system.
• 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
assemblies completely.
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
administrator.
Parts Required
Description
Finis Code
Quantity
Resistor wire
1 715 479
2
Headlamp bulb H7
see FordEcat
-
Labor Time
Operation Description
Operation No. / Time
Resistor Wire Install On Both Headlamps - Fiesta 2008.75
Includes: Headlamp Assembly (Left-Hand Side) Remove And Install
710041C65
Resistor Wire Install On Both Headlamps - Kuga 2008.5
Includes: Loosen The Headlamp Assembly On Both Sides
710041C65
Repair/Claim Coding
Causal Part:
36319
ACES Condition Code:
42
OASIS
201200, 203200
Production Action
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.
Service Instruction
See Summary.
Resistor Wire - Install (On Both Headlamps)