This 2006 Ford Five Hundred came in with the complaint that the driver’s side low beam headlight went out and after changing the bulb the owner found that it would stop working and she would have to wiggle the wires to get it working again. I disconnected the harness and the problem was quite evident. A burnt harness connector.
I looked through our stock and found that we do not keep the original type in inventory but we do stock a universal sealed connector for a 9006 bulb which is what this vehicle uses. I did a quick test to make sure the finished assembly would fit and it did.
Then it was just a matter of cutting out the old and splicing in the new. To order this connector please click here.
I staggered the joints and heated the heat shrink tubing.
Taped then harness back up.
Installed a new bulb and plugged the connector into the bulb. Luckily there is enough room to do this without taking anything apart. The small piece of tape shows about where the bulb is.
A view from the engine side. You can see the blue spot which is part of the harness connector below the tape strip.
Discovered both of my wife’s 2005 Ford Five Hundred headlights did this. Who knows how long she has been driving with just fog lights. I’ll be replacing them tomorrow. Thanks for this post when I started searching for the fuse location I found your post and decided to check the wires. Just like your customer when I wiggled them they came back on.
Thanks Sparky exact same issue just 1 week ago. I will get this corrected.