Ford Electrics are a big PIA. Get a repair manual for the car. Get a DVOM and in your spare time start from the headlights and work back to the light switch. Look for the power draining with the meter. Start by checking the connections and then the individual wires. It's a long tedious process usually better left to a qualified ford mechanic. It's probably a bad switch though.
SOURCE: 2004 ford crown vic. intermittant probs with low/high beam.
I finally bit the bullet and took it into the dealer. It was indeed the Light Control Module (LCM). The dealer said there was not a service bulletin issued on this problem but when I asked the service manager to talk to the Ford rep about assisting with this safety issue, it took all of ten seconds for him to come back on the line and say that they would fix the whole thing for $100. (My car is not under warranty and the LCM alone is $480). Not sure exactly what happened behind the scenes but it appears Ford would rather fix this than have an issue made of it. (This is a privately owned car that does have wigwags and other emergency lighting equipment installed. These were not a factor).
SOURCE: 1999 FORD CROWN VIC. 4.6 - PROBLEM, NOISE
This is caused by the IAC valve. Over time the valve becomes gummy and inoperative. Get it replaced and the problem is solved. IAC stands for idle air control, hence the stalling concern.
SOURCE: 93 Camry Headlight Switch
From the symptoms you describe it sounds as though your headlamp switch is dirty, broken or out of adjustment. I would disassemble it and find out what is going on.
SOURCE: 2004 Crown Vic- Headlights come on when first
There is a resistor in the light control module under the driver side of the dash. You can replace the whole module which is about 100+ dollars or if you're good with soldering, replace the resistor. You will need to remove the box and open it up. Find out the resistor part number and replace it. This is a common problem on the 03-05 crown vics. Good luck
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