Ok so yesterday the wife went to leave for work and came back in and told me she had a Headlight out.
I said ok I will look at it later. She proceded to work.

Today I put in a new bulb but still nothing. I said ok and checked the fuse for the L/S lowbeam which was out.
Fuse was blown. Install a new fuse and try. The fuse blows right away. I look closely in the headlight.
I see all the insulation on the wires cracked and falling off.

So if you run into this problem as well here is how you fix it.

I had a spare assembly in the garage with no glass because it was broken but the wires were the same way.

1.Remove the headlight assembly from the car. There is 3 10MM screws holding it in. But first you need to remove the parking light.You will also have to remove the plastic trim under the headlight it just pull straight off.

2.Once the light os out of the car using a table,cart, or tool box tray remove all the clips holding the glass to the assembly. It will look like this.

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES011-1.jpg)

3.Once the glass is off then you can pull the crome assembly out. It clips into the black part.Once you get it apart you will see how it goes back in. It will look like this. (Except I already took the harness out)

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES012-1.jpg)

4.Next you will remove the harness from the headlight assembly it is held in by little clips on the plug.
Then you will need a real little screwdriver like an eyeglass one.Using a flashlight look in the plug closely where the little notch is one of the side you will see a metal tab from the connector.Use the screwdrive to push the tab in and release the connector and slide it out of the plug.

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES013-1.jpg)

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES014.jpg)


5.I had to use a couple different sizes of heatshrink. On the Yellow and white wire it was the same size.
You slide the heatshrink over the terminal and slide it all the way to the other connector. Then use heat to shrink it. You might need to use 2 pieces of it.
For the brown wire since it is shared between both connectors I removed the terminal from the bulb side of the plug. Then I had to use a little bigger size of heatshrink because the terminals are a little bigger.It doesn't have to fit 100% tight (It would be nice to have it) but once you get the wire all full with it and secured back in the plug it can't go anywhere.I had to use 2 pieces on the brown as well. I shrunk the first piece then slide the second piece over the first a little and shrunk to help hold it tight.

You can see from the pics how bad the wires really were.

Here is a few pics of after. (don't mind the different colors thats all I had at home on such short notice)

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES016-1.jpg)

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES017-1.jpg)

(IMG:http://img.photobucket.com/albums/v624/mustang8719/PICTURES018-1.jpg)

When reinstalling the terminals back into the plugs you might have to adjust the little locking tab on the terminals.
Then reinstall everything including the light back into the car.

Hope this helps someone out there.

funny thing is I did almost the same thing about a week ago because my pass side turn signal assembly just stopped. the fuses just went. when I opened it up, the harness was completely rusted, the blades were fused to each other. that was a new one to me. anyway, i just cut and pasted with a used one from the junkyard. and I made a little rubber bootie because I can't figure out where the water came to rust it out like that. I've got to find it a post a picture to show you guys. this thing was like one piece. weird. thanks tech.

No problem if you find it I would like to see a pic of it.

excellent presentation and explanation...helped me...thank

Your Welcome!!