Found it. Open in the headlight signal splice. Not worth taking it back to the dealer. I don't have the time or patience for them anymore. Thanks for all the advice and support!

Maybe you don't have the time or inclination to deal with the hassle from the bastards in the service department, but maybe a well-written letter to the dealership's general manager outlining the problem, and how you solved it yourself would produce some action from the owners. Maybe a free oil change or something... at least it would let you vent your spleen and get it out of your system. And perhaps some schnook will get a well-deserved ass-chewing.

And if there is a problem with the recall parts it will save the next customer a big headache.

I have a 2003 Crown Vic with DRL. I always operated it with all lights on all the time. Now when I first start it I have high and low beam and high beam flasher working. After a short time the high beams no longer work, although I still have high beam flasher. There is an audible click from under the dash when I lose high beams. Is this a recall item or is it the LCM I need ???

Sounds like the recall would apply to you. The recall is installing the external relay and removing/bypassing the internal one on the LCM. So if your headlights go out, but you still have the hi beam flash to pass, then yes, take it in.

Thanks for the quick reply. Have car booked in to have it checked out. P.S. I had a 2003 XC70 AWD. Loved that car for comfort and a real drivers car, but at 250,000 miles got a little nervous so I sold it.

If it was the non-turbo version that's just getting broken in, like the Crown Vic.

The clicking under the dash is the relay kicking on and off, btw. I had a 2005 model with a bad LCM and did the external relay myself, there was a group of us who had done them, Ford finally listened 5 years later lol

Since PhotoSucket is down I'll re-share the pics again.

Man that looks like a hack job, when I did mine it was much neater.

Should have read this thread before taking mine to the dealer for the recall today!!!
Naively assuming that they would just pull the LCM out and replace it, I made a 3pm appointment this Friday. The "service advisor" advised that they may need to keep the car till the end of the day. "What?" I wondered, "3 hours to replace a box under the dash that's held by a couple screws?" She waved a pile of paper in front of me, and said: "I have the procedure; Ford allows 1.3 hours to do it". Sitting in the waiting area I got curious and googled for the procedure. That's how I found the strange hack job that they are doing with splicing a dozen wires and hanging an external box. Should have never gone to do this, I thought, but it was too late. After sitting there for better than an hour, the lady comes and says: "We cannot finish the job today, you will get a rental" "And what has been done so far?" I ask. "The tech is still studying the diagrams," she responds. Obviously it's the first time he is going to do this job. If he manages not to mix the wires and not to leave anything open, it's going to be a miracle.
A guy shows up and drives us to the rental place. We wait, then are subjected to the usual rental business practice to push all manner of unnecessary insurance. They also put a $100 hold on my credit card, "just as a precaution". They also inform me that Ford authorized only a 24-hour rental. "What happens if they are not done with my car by then, I ask." "You will have to pay and deal with Ford for reimbursement". Then comes the inspection of the rental clunker for dents and scratches and arguing whether what I see should or should not be marked on the form.
Hopefully that's where the punishment for not reading this thread before going to the dealer ends, but we'll see. Story to be continued...

The dealer will NOT see my car for any of the LCM shenanigans.
Nope!
Uh-Uh!
Ain't gonna happen!
Noway!

The hackery so far does not inspire confidence. A dealer tech piercing wires? Unacceptable. Back probe, do it properly. Piercing wires long term is detrimental to wiring. Of course, many techs also feel that once a car is old people get rid of it, and they don't give a crap, just lipstick on a pig. Make the cover look pretty, who cares how its done behind.

This is one of the most ludicrous hacks I've ever seen...I can't even...

Brand new LCMs sell to the public for $157 at tascaparts. Obviously Ford pays way less than that. Is it really cheaper to pay a tech to install this abortion than to slide a new unit in?

Just proof that the cars that this applies to have a poorly designed LCM and Ford has opted to use a piggy-back box to address the issue, hopefully permanently.

Alex.