Need some help from members of my issue. About a month ago had a headlight bulb failure warning for OS. The problem became intermittent as the bulb starting working again a few times until I had chance to replace several days later. 

I swapped for a new bulb and low and behold the new bulb started suffering the intermittent failure/warning issue on Maxidot. Now it’s not a false warning, the bulb is off but does turn itself back on eventually, maybe a few bumps of the road. 

This weekend because I had the chance. I checked the bulb and cables seemed all ok. 

When it happened I slowly slid out the headlight unit. Opened the door to the bulbs area. Nothing happened until I touched the bulb from the rear and it started up. I still say there was nothing wrong with the fitting and it’s fine. I removed the lamp connector plug and sprayed wd40 type stuff before refitting the connector. The car is a 230k miler and it’s had permanent headlights on day and night for the last 30k at least. I use them as DRLs as it’s used for mostly motorway driving and too many people have trouble seeing you in any light. Is this some earth issue ?

 

It sounds like you may have an intermittent connection in the wiring in the headlamp connector. Can you get a voltmeter onto the pins to see what happens when you waggle the wiring?

 

One of the female connector terminals needs squeezing up to make firm contact, it is gripping on one and making intermittent contact on the other, might be heat related due to use as DRL.

As above, from what you've described it sounds like a intermittent electrical connection in here somewhere...

 

 

Having your dipped headlights as DRL's will be exposing the connector and wire to some prolonged, and during the summer months, excessive heat.

 

A couple of new connectors and she'll be good for another 230,000 miles!

Thanks all will try the basic suggestions first and then think about more invasive changes.