Chingon Posted December 23, 2013 Share Posted December 23, 2013 (edited) So I've seen this issue with my old lady's 2009 Edge tail lights - the bulb burns out and appears to burn/melt part of the harness with it. I searched those forums and it was a common issue with no recall/remedy. Recently, my passenger headlight went out and while replacing it I saw that the harness looked awfully burned up as well. I went ahead and replaced the bulb and it does appear to work as normal, but I'm a bit concerned obviously. Has anyone see this before? I'm coming up quick on 36k miles so I'd like to get it replaced if possible... Edited December 23, 2013 by Chingon 0 Quote Link to comment Share on other sites More sharing options...
BlueOval2010 Posted December 23, 2013 Share Posted December 23, 2013 If the wires are burnt or melted then that's a big problem. If the wires are just a little discolored then that might be normal. I'm guessing you're not blowing fuses as you didn't mention that, but it's odd that the headlamp could pull that much current without blowing a fuse first. This sounds like a trip to the dealer to diagnose the problem. Please update this post if you figure it out - thanks. 0 Quote Link to comment Share on other sites More sharing options...
Chingon Posted December 29, 2013 Author Share Posted December 29, 2013 I assumed even a burned-out headlight would be covered under the 3yr/36k mile warranty, but a call to the service tech said it would not be covered. WTF? I replaced it myself, but just last night at the gas station the same headlight did not turn on when I started my car. Turning the lights off and back on got it to light up finally - something's definitely up. Now I have to wait until Monday to get it in the shop, and my mileage is at 35,96X miles! 0 Quote Link to comment Share on other sites More sharing options...
drolds1 Posted December 29, 2013 Share Posted December 29, 2013 I assumed even a burned-out headlight would be covered under the 3yr/36k mile warranty, but a call to the service tech said it would not be covered. WTF? I replaced it myself, but just last night at the gas station the same headlight did not turn on when I started my car. Turning the lights off and back on got it to light up finally - something's definitely up. Now I have to wait until Monday to get it in the shop, and my mileage is at 35,96X miles! That's odd. Did you speak to a service tech or a service advisor? A tech might not know what's covered but an SA can look it up. If you're still under the B2B warranty, a non-working headlight is covered. It is between the bumpers, isn't it? Let them show exactly you where in the warranty guide this is excluded because I'm not seeing it. Furthermore, I had this issue with a 2003 Lincoln LS. I had to smack the headlight to make it work. They replaced the entire headlight assembly under the B2B warranty. You might have to take this up with the SM if you get no satisfaction. 0 Quote Link to comment Share on other sites More sharing options...
Chingon Posted January 2, 2014 Author Share Posted January 2, 2014 ...the saga continues. I was told by a service advisor in person that headlight bulbs are not covered under 3yr/36k mile warranty. However, the pigtail (not the actual harness I guess, just the connector) was burned up and Ford was going to replace it.... UNTIL they realized that the headlights are reman'd parts, not genuine Ford OEM. They consider the pigtail connector part of the headlight assembly and wouldn't touch it. When I bought the car new off the lot, I was caught in the middle of a 5-car pileup when some lady slammed into the car behind me at 35+ mph. Oh, this was within 48 hours of buying the car. This crap just never stops with the car - now I have a new car with no warranty on anything in the front/rear of the vehicle. I'm not paying for it, but I still have to take it to a shop with no rental and wait days for adjusters to come out and ok replacements. What a pain. 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted January 2, 2014 Share Posted January 2, 2014 That's why it's important to make sure any repairs use OEM parts. Can't say I blame Ford in this case. 0 Quote Link to comment Share on other sites More sharing options...
Chingon Posted January 2, 2014 Author Share Posted January 2, 2014 That's why it's important to make sure any repairs use OEM parts. Can't say I blame Ford in this case. I demanded OEM parts, but since the lady immediately ran into liability limits I had to start the claim through my own insurance (GEICO). According to the policy, you are forced to install aftermarket when filing a claim under your own policy. If it was her policy paying - the demand would have been met. However, I just got a call from the adjuster and they decided to install new OEM parts after seeing the after-effects of crap parts... 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted January 2, 2014 Share Posted January 2, 2014 I demanded OEM parts, but since the lady immediately ran into liability limits I had to start the claim through my own insurance (GEICO). According to the policy, you are forced to install aftermarket when filing a claim under your own policy. If it was her policy paying - the demand would have been met. However, I just got a call from the adjuster and they decided to install new OEM parts after seeing the after-effects of crap parts... Hi Chingon. It seems you were given incorrect information by the service people you spoke to. When we purchase new, we are all given a Ford Owners Warranty Guide. It lists all applicable warranty coverages and rights in detail. If you read the Warranty Guide, the bulbs are covered. I thought bulbs were on the list of courtesy items only covered for 1 year and XX miles (such as wiper blades, brake linings etc.). However, when I just checked they were not on that 1 year courtesy item list, nor are they listed as an excluded/non-covered item (unless I missed something). If you lost or can not find your copy, you can download the PDF version here - http://www.flmowner.com/servlet/ContentServer?pagename=Owner/Page/IdentifyVehiclePage&BackToLogin=Owner/Page/OwnerGuidePage&ord=91325628 As always, I would recommend everyone read their Warranty Guide, especially when we have questions as to what is/is not covered. Why rely on someone who may or may not know and/or perform their job properly? Yes, Dealership employees should perform their job properly, but we should also use the resources available to protect our own rights. Of course, you unfortunately had the added issue of the non-OEM headlight housing being installed after an accident, giving the Dealership a dubious out on the bulb replacement. But as you stated, it seems your insurance company has now approved proper OEM parts for re-installation on your Fusion. Good luck. 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted January 2, 2014 Share Posted January 2, 2014 You missed the part where he had a wreck and the headlamps were replaced with non-OEM parts. That's why Ford wouldn't cover them - they weren't OEM parts. 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted January 2, 2014 Share Posted January 2, 2014 You missed the part where he had a wreck and the headlamps were replaced with non-OEM parts. That's why Ford wouldn't cover them - they weren't OEM parts. Hi Allen. Nope...see my next-to-last paragraph (before "Good luck."). Don't worry, I am still recovering from New years Eve too! LOL I was referring to post #5 where Chingon states "I was told by a service advisor in person that headlight bulbs are not covered under 3yr/36k mile warranty...". Good luck my friend. 0 Quote Link to comment Share on other sites More sharing options...
thefoeyouknow Posted January 3, 2014 Share Posted January 3, 2014 I've only seen these melt at all when High Wattage bulbs are used, such as the 80watt and 100watt bulbs that the parts stores sell, but fail to warn about. These are not DOT approved and can as much as double the current being pulled through the terminals wires and FETs in the system. Make sure you don't have these. They'll melt everything and can eventually cook your SJB if you've got them for low beams. 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted January 3, 2014 Share Posted January 3, 2014 Hi Allen. Nope...see my next-to-last paragraph (before "Good luck."). Don't worry, I am still recovering from New years Eve too! LOL I was referring to post #5 where Chingon states "I was told by a service advisor in person that headlight bulbs are not covered under 3yr/36k mile warranty...". Good luck my friend. Oops. You're right as usual. 0 Quote Link to comment Share on other sites More sharing options...
Chingon Posted January 3, 2014 Author Share Posted January 3, 2014 Yeah I had OEM bulbs, and I replaced it with Sylvania's from Autozone, but they were identical bulbs. I don't know what it was, as the aftermarket headlight assembly lacked some fit and finish, but was otherwise factory "looking". I doubt that had anything to do with the factory pigtail connector/factory bulb melting, but I guess we'll see... 0 Quote Link to comment Share on other sites More sharing options...
Linc Posted February 13, 2017 Share Posted February 13, 2017 I purchased my 2010 just over a year ago and have experienced this problem on my drivers side headlamp. The light was find for a long time, say close to 9 months and then it went out. I bought a bulb not thinking anything of the situation at all. But when I went to replace it, the old one came back on when I touched the wires, so I left it alone. At this point the light would go on and off randomly. So I went to change the bulb and found the actual plastic melted where the wiring contact the bulb. So I snipped off the end and grafted on a new plug. Several months later the problem returned and upon inspection I noticed the same melting starting to occur. So this time I put in the new bulb, thinking the bulb might be the problem. Now this week I am back to a melted socket and a light that will not stay on. It appears the headlamp on that side is a reproduction like the original poster of this thread. Since I wanted to upgrade I just bought some LED units and spoke to the manufacture about the bulbs and wiring. They told me they would honor a one year warranty without question, which I made them put in writing. When the arrive I will install them and see if things get better. I did check my bulbs based on this thread and did see that they were NOT the 80 or 100 watt units. 0 Quote Link to comment Share on other sites More sharing options...
Oracle_Ed Posted February 13, 2017 Share Posted February 13, 2017 It would have been better if you had replaced the harness and the bulb at the same time. It is likely that the original bulb contact area was high resistance and that caused the replacement harness to overheat also. 0 Quote Link to comment Share on other sites More sharing options...
Linc Posted February 13, 2017 Share Posted February 13, 2017 Probably so. I guess when the new lights get here I will be starting with that situation. 0 Quote Link to comment Share on other sites More sharing options...
JESSE SCHILLINGER Posted July 19, 2018 Share Posted July 19, 2018 so I am having the same issue, I have 230,000 miles and the bulb will burn out in like 2 days and the wires all melt. Have replace 3 times now and it just keeps happing, any one have a fix for this yet? 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted July 19, 2018 Share Posted July 19, 2018 (edited) 3 hours ago, JESSE SCHILLINGER said: so I am having the same issue, I have 230,000 miles and the bulb will burn out in like 2 days and the wires all melt. Have replace 3 times now and it just keeps happing, any one have a fix for this yet? Hi Jesse. Are you using the correct bulb as per your Owners Manual specifications chart? What bulbs are you using (manufacturer, model, wattage etc.)? How long have you owned this car? When did this problem begin? If you are not using the proper bulb as per the Ford specification, that is most likely the cause of your problems. Edited July 19, 2018 by bbf2530 0 Quote Link to comment Share on other sites More sharing options...
drolds1 Posted July 20, 2018 Share Posted July 20, 2018 Are they OE headlamps or aftermarket? 0 Quote Link to comment Share on other sites More sharing options...
Linc Posted July 20, 2018 Share Posted July 20, 2018 So for my issue, the headlamps in the car when I got it were reproduction, not OEM. I bought 'better' and 'different' non OEM headlamps and have not had a problem in the last 100k miles. So knowing what I know now, I would make sure the headlamps are not cheap reproduction units. 0 Quote Link to comment Share on other sites More sharing options...
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