KA headlamp is very difficul to access.
That so many KA's are driving around with a lamp out is testimony to the problem.For the future the construction and use regulations should be ammended to compel vehicle manufacturers to make lamp change simple for owners. We should be able to do this as a simple roadside repair rather than driving around with a lamp out because even some garages can't do the repair.
As various previous posts state it can be done if you are blessed with very small hands. If you have bigger hands it is very difficult. Here's my method:
(Offside) remove 10mm hex screw on lamp unit upper bracket. Remove 10mm hex screw at bottom on lamp unit adjacent to grille. Remove 3 phillips screws retaining grille to crossmember. Spring the grill forwards. Pull firmly on the wheel arch\ bumper at the front and it will pop out leaving the retaining clips in the front wing. Spring the joint in the plastic bumper where the center section joins the offside section. At this point if you are unlucky you will probabally break the plastic snap joint bits (read on how to fix). Anyway when you have sprung the joint you can now push the offside bumper section down a little to reveal a third 10mm Hex screw which retains the lamp unit at the back adjacent to the os wing.
Use a 10 mm socket on an extension bar to release the hex screw. The lamp unit can now be draw forward and access gained to the cover,spring retaining clips, and lamps. Remove and insert new H7 lamp (tab uppermost) refit clips and cover. Reassemble is reverse order. If you had the misfortune to break the plastic snap joints on the bumper joints simply trim them off. Push the edges of the bumper sections together and insert a couple of round head self tap screws about 10 mm from the joint to retain the two parts. Done carefully it will be almost invisible and makes the next lamp replacement easier! A note on lamps. Several contributors comment about short life lamps. (Until its recent demise I worked for forty years manufacturing automobile lamps in the British lampmaking industry).Unfortunately there are now considerable number of low quality lamps on the market some bearing the logo of well known brands.
Buy your replacement lamp from FORD. You will be buying orignial specification product. I know from experience Ford set the highest standards. It may cost a little more but its worth it.
Keep the receipt. If the lamp fails return it and insist upon a refund. If you have no alternative go for one of the German or Dutch brands. Be aware that many replacement lamps are poor quality with incorrect focus, poor filament design and construction, low quality gas fill,air leaks etc etc. Buy Ford\Motorcraft.
If the lamp fails take it back to the retailer and play hell. Dont be afraid to go to trading standards. Remember that when the cars were new they had a guarantee for a period of time.You should expect your original manufacturers replacement part to last a similar length of time.
Too many retailers are selling low quality inferior lamps and getting away with it. Lamps are safety critical products. If we all insist that they are fit for the job maybe one day we can drive out the rubbish.
Stu.
November 2011