So, I've got a writeup for the 4th gens...........time for the 02-05s!
Items needed for the install:
- Headlights!
- Morimoto Projectors
- Shrouds of your choice
- BiXenon HID Kit
- Quick Disconnects (2 sets), might not be needed.
- Oven
Headlights (clear corner lights purchased from eBay):
Projectors and Shrouds (Gatling Gun):
BiXenon HID Kit:
Get ready to bake fellas! (only time I use the oven)
Check lights - kinda weird, this one had syran wrap under the lens (they cover the lens with syran wrap.......somehow this one had it under the lens!) - make note so you can take that out later.
Bake. I baked these for 6 minutes at 250. There are 3 tabs on the top of the headlight, 2 on the bottom and one on the inner (grill side) of lights. After they come out, use a flat screwdriver to lift those tabs up, them pry the lens open. Pretty quick on the 02-05 lights. Be sure to wear some leather gloves, don't want to burn your hands! When its done - here's what you have:
Lens and Bezel (as I wasn't painting this set, I left them intact, no need to separate):
Headlight housing:
Remove the thing that covers the bulb, few wiggles and its out.
The Morimotos are a bixenon projector, so they have a solenoid that controls the cutoff shield. That solenoid has 2 wires, those need to find their to the back of the light. Easiest way - drill a hole.
I used a 3/16" bit, picked a spot in the middle of the flat spot where the bulb cover thing slid into. Slide your wires through that hole.
Hey, new parts! Yeah, I missed a pic - the projector is installed in the pic. Here is is from the front. I put blue tape over the projector when I work on them - don't want them to get fingerprints and crap on 'em.
In your kit you will have a rubber o-ring. That slides onto the shaft, then you install the Morimioto projector into the housing. On the back side, slide on the 9007 adapter, then the nut. Use a pair of needle nose pliers to tighten the nut. Next, install the bulb holder. 3 screws, done. Watch the screws.......the heads are very weak and they will round off FAST. Trust me.
Projector installed:
Install the bulb:
Slide the shroud into place
Install some sort of quick disconnect wires on the back of the solenoid wires. This is the 3rd set of Morimotos I have done, and the first 2 came with a connector..........these didn't. Unfortunately.......I didn't keep the ones from the first sets (which I cut and hardwired - different setup on those though). Anyway, I got 2 sets of disconnects from Radio Shack for less than $5.
Don't forget to change the wiring on your harness to fit the quick disconnects (again, if needed).
Take the lights out to the truck, aim them as best as you can (you can adjust them more later - no biggy, just get 'em close for now). Make sure the lights work, all that jazz.
Head back in, time to seal it up! As these lights were brand new and the glue seemed very pliable, I didn't remove it all to install butyl tape. I removed the bulbs, popped 'em back in the oven for 4 minutes and reinstalled the lens. Get the clips back on while its still warm! I then put some butyl tape around the hole I drilled for the high beam wires, don't need a place for moisture to get in!
Take some time to take some pics!
Installed pics will be added later, after the customer gets them in!
Linear Mode
