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Old 03-02-2013, 02:40 PM   #1
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00-04 headlight disassembly for harness replacement

I recently had 1 of the plugs that goes directly into the bulb completely disintegrate and I need to replace the harness (I have a 03 ZTW). I have searched the threads and how-to's and found nothing on how to take a part a headlight so this harness can be replaced. Can anyone help?


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Old 03-02-2013, 05:41 PM   #2
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Do you have a picture of the part your talking about

One way the fix something inside the headlight is to get a "new" one. One from a salvage yard should be pretty reasonable and you can also buy them online.
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Old 03-02-2013, 06:11 PM   #3
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Originally Posted by 02fordsvt View Post
Do you have a picture of the part your talking about

One way the fix something inside the headlight is to get a "new" one. One from a salvage yard should be pretty reasonable and you can also buy them online.
I do not at the moment but it's the harness you would pull off to change the bulb if it was burned out. I was looking at upgrading the harness and plug so this wouldn't happen again.

If you need a pic I can get it.
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Old 03-02-2013, 07:06 PM   #4
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If someone else isn't able to get you an answer, a picture would help me help you a bit more.

BTW I just remembered, I have two junk headlights sitting in my closet. If you want an OEM replacement, I can send the you a replacement part from them for the cost of shipping.
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Old 03-03-2013, 01:59 PM   #5
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Ok, here are the pics you needed to see.....the 2nd pic shows the broken plug, the 3rd pic shows the end of the harness but to get this harness out I need to separate the housings.





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Old 03-03-2013, 10:29 PM   #6
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the harness that connects to the bulb is very easy to change. Just cut the old one off and wire a new one in.

I cant tell if the plug that is attached to the actual headlight (where the car harness attaches) is missed up or not..

if it is you will need to bake the headlights apart and try to replace it



if you need help with anything let me know
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Old 03-03-2013, 10:33 PM   #7
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you can buy that plug from Ford. don't know the part number off the top of my head.
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Old 03-04-2013, 01:44 AM   #8
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The headlight assembly is heat glued together and not intended to ever be taken apart. Not that someone couldn't do it but getting it back together and still sealed to not get condensation will be problematic......................
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Old 03-04-2013, 01:52 AM   #9
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That looks like the culprit of useing 90/100w bulbs. You really shouldn't go higher than 55watt in stock housings with out upgraded wiring anyways.

There are several thread where people have put the housings in the oven to soften the glue in order to open them up for either a reto-fit, repair, or painting.

Ill try to find you a couple real quick to help yea out.

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Old 03-04-2013, 02:15 AM   #10
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Here's a retrofit, it mentions the oven instructions about half way down the first post.

How-To Retro-Fit Stock Headlights W/Projectors

Here is another with oven instructions.

08 Focus Headlight Baking Recipe





Here's one for Resealing.
http://www.focusfanatics.com/howtos/resealingtaillight/
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