My headlights go out at LEAST once a month. It is the most annoying thing in the world and I am constantly being pulled over for it. The headlights are also very hard to change out, it takes me over a hour to do it. Does anyone have this problem??? I have checked my fuse, but they are not blown. I don't know what else it could be?
It could either be a poor connector or water entering the housing. Also, are you making sure that you're not touching the glass of the bulb when installing it???
Check the battery charge voltage by putting a voltmeter across the battery terminals and revving it a bit. It shouldn't go above 13.5 volts, preferably a bit less. If it's higher, that means the alternator voltage regulator has failed and it's "cooking" electrical components. Probably means a new alternator.
Check out the website www.newbeetle.org There is a lot of helpful people and great information on there.