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Old 02-03-2013, 07:53 PM   #1
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Keep burning out Driver Side Low Beam Headlight Bulb

I have a 2003 SE Sedan and the low beam filiment keeps burning out on the drivers side. I have the Sylvania Ultra Stars this last burnout incident. This has happened 2 times in the last 3 months.....drivers side only.


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Old 02-03-2013, 10:10 PM   #2
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I'd inspect the wiring (for obvious continuity problems, exposed wire or corrosion - orange/green wire), headlamp socket (for corrosion, melted plastic or burns) and fuse (one per side for low beam circuit - Fuse 16, 17, iirc).
Somewhere in there you should find something suspicious.
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Old 02-06-2013, 09:09 AM   #3
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I don't know if the Focus has the same setup, but I had this problem on both a '99 & an '02 Saab 9. My lights would last longer than yours, but were still dead after only 5-6 mos.

The source of the constant single-side burnout problem was a headlight relay. On the GM/Saab 9 it's a bright orange plastic case about 1-1/4"x1-1/4" sq & about 2-1/2" tall. The easy fix is to buy a new relay, but the OE part is $150+!! (3rd party parts are cheaper.)

The actual cause is cracked solder joints where the relay's circuit board mates to the connector base. The theory on the Saab boards is that constant vibration is rapid-cycling the current across the broken joints, dramatically shortening the life of the bulbs. I carefully pried the orange case off the base & reflowed additional solder to board-to-base joints.

This cured my burnout problem & my lights now go for years between burnouts.
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