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MustangMatt96GT
03-05-2012, 09:58 AM
Well after driving my truck close to a 1000 miles a couple weekends ago all at the dark of the day, I came to the conclusion my head lights really didn't cut it. They have had different bulbs in them and are starting to yellow. So I decided it was time to do what I have always wanted. A HID kit.

Now yes there is a proper way to do an HID kit and an improper way. The improper way takes a normal headlight and puts a cheap HID kit in it. The problem with any HID kit, is that when you put them in a non projector style housing, it creates a great amount of scattered light, and in the end basically wastes the output of an HID and blinds oncoming drivers.

The proper way to do it is to use a projector style head light. Right now there is nothing produced for our old trucks without getting a ricer style off ebay. So I decided to do some research and figure out how to do my own.

This is what I used

Headlight Housings (http://www.ebay.com/itm/190588435445?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649#ht_4539wt_1210)
Projector/Ballasts/Bulbs/Harness (http://www.theretrofitsource.com/product_info.php?products_id=227)


So I got the housings here at the house, and actually was very surprised by the quality.
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1454.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1456.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1457.jpg

Now was the time to take the lenses off the housings so I could put the projectors inside the housings. This took a lot more work than I expected, but after about an hour and putting them in and out of the oven I finally got them off. The main trick I learned towards the end was to leave them in longer. I was afraid I would melt the housings, but even at 275 degrees and 10 minutes there was no issues.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1459.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1460.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1461.jpg

Now that the lenses are off, its time to put the retro fit projectors in.

First lets put the shrouds on the projectors, there are 4 screws to tighten them on. Not tough to do, but if forgotten to do, you gotta take the next steps apart to put back on.

Because these trucks come with a 9007 bulb stock, I got some of the 9007 adapters when I ordered the HID setup.

Without the Adapter
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1469.jpg
With the Adapter
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1470.jpg

The flat spot with the two ears on the top is the guide for the Projector to slide though and be properly aimed. The two ears on either side are for the wires to go through that are used for the shield solenoid or the High Beams.

The kit comes with a few pieces. I used the big silicone white washer right on the projector, then the projector was fed through the housing while aligning the wires, and then I put the lock nut on them. The wires seem to get in the way a bit, but if you kinda push them down and out of the way of the lock nut its not terrible to tighten up. I just used a pair of needle nose.

Here is what it looks like with the lock nut on.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1462.jpg

After those are tight, you can screw the bulb holder back onto the projector.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1465.jpg

Then the bulb can slide in.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1467.jpg

Here is what the other side looks like.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1464.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1466.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1471.jpg

So now that everything here is done. Time to put the harness for the high lows on, which is not hard at all, the wires just slide in, but you have to make sure the black goes to the black. The harness other wires are Blue and Red. The Projector wires are Red. So the Red goes to the red or Blue, and the Blacks go to the Blacks.

Final step is resealing the Housings. I bought the extra sealing glue to seal these back up. Take a strip of it and put it on the down the housing edges. Error on the out side of the housing (I did this on one, and the other I didn’t), otherwise you can see the glue on the inside.

Once the stripe of glue is on both housings, put them in oven at 265 degrees for 8 minutes. Once you take them off, make sure that the lenses are clean and not printed up, as well as the reflective part in the housing. Then take the lenses and press them on. Make sure they are nice and tight. Wait for the glue to cool down and trim down the excess glue.


This is what they look like now. Ready to go in the truck.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1472.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1473.jpg



To take the header panel out of the truck. Take the grill out, there are 5 screws on top and one under the Ford Emblem. Next take the two screws out of the chrome trim piece around the head lights.

The trim piece is attached to the side marker and the lower housing. The lower housing then has 2 11 mm bolts hold it on that you have to take off from the back side of the radiator support.

Once those are out, you can take the bulbs out and you are left with the two head lights on the truck and the header panel The header panel has 11 8 mm bolts holding it on. Take them out and then take the header panel off the truck with the headlights.

I then took the stock headlights and matched the new headlights screws and everything, so that they would be close in alignment. Then I installed them into the header panel.

I had to find a place to mount the ballasts for the HIDs. I used the back of the header panel.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1475.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1476.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1477.jpg

Now lets put the wiring harness in the truck.

12V source I put to the always hot side of the starter solenoid. The ground I found a place to put right near the passenger side battery. I ran the long wire segment to the drivers side in front of the radiator and A/C condenser. Then I brought the Header panel close and plugged everything in.

Thick black and red wires went to the ballasts. The Ballasts then were plugged into the bulbs. The high beam setup was blue and black. The projectors had the red and black. The red goes to the 12Vs (blue wire) and the ground goes to the blue.
Now the part that hooks to the input, is originally wired for a 9004 bulb. So the wiring there needs to change.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/9004_9007.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/76ca10ab.jpg

Simple swap. Now time to test and see if everything is working.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1479.jpg

Now its time to reassemble. And do a final aiming of them. 25 feet out, the cutoff line from the projector should be 1-2 inches lower than the point they are on the truck.

Finished product!

http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1482.jpg
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1483.jpg

Low beams parked parallel to the wall, makes a nice cutoff.

http://i174.photobucket.com/albums/w96/MustangMatt96gt/46bdcf6f.jpg
Low beams
http://i174.photobucket.com/albums/w96/MustangMatt96gt/52aab4ca.jpg
Brights
http://i174.photobucket.com/albums/w96/MustangMatt96gt/IMG_1499.jpg

Drove quite a bit last night, and I love these things! They are amazing.

03_PSD
03-05-2012, 10:38 AM
looks fantastic!!

skew12
03-05-2012, 10:42 AM
Thanks for the great writeup. I've got an extra set of 05 Harley's that I'll attempt this on in the near future.

TheSmokinStroke2002
03-05-2012, 11:03 AM
Great write up!!

Sent from my ADR6400L using Tapatalk

03 tx pwr stroke
03-05-2012, 12:12 PM
Sub'd. Great write up!:thumbup:

Hotrodtractor
03-05-2012, 12:21 PM
Glad you brought this over here.

MustangMatt96GT
03-06-2012, 02:06 PM
This was my last truck. As soon as I get the coin to do this again, the new truck will get some, even though it has a Ranch Hand on it and I might get some bad reflections off of it.

At night there is nothing like driving a truck with HID Projectors. I have ridden in trucks with just HID bulbs and there is no comparison. I had silver stars before and comparatively with those on and these HIDs on, the silver stars look like nothing is on.

Hotrodtractor
03-06-2012, 02:11 PM
This was my last truck. As soon as I get the coin to do this again, the new truck will get some, even though it has a Ranch Hand on it and I might get some bad reflections off of it.

At night there is nothing like driving a truck with HID Projectors. I have ridden in trucks with just HID bulbs and there is no comparison. I had silver stars before and comparatively with those on and these HIDs on, the silver stars look like nothing is on.

I'm looking at fitment right now on setting up my Dmax with a set of HID projectors - Probably going to install either a pair of Bi-Xenon projectors and a set of 90mm Hella halogen projectors so my low beams are HID and my high beams are HID and halogen - or do a quad Bi-Xenon setup - it all depends on my packaging in the bulb housings I have to work with because they are very small for doing this. By doing the mixed high beam - I can have halogens to "flash" people with for passing on the interstate, warning them, whatever, and have been told that the mixed high beam light helps even more - all while not having to worry about lining up and adjusting the cutoffs on 4 projector setups split into two housings.

03 tx pwr stroke
03-06-2012, 02:12 PM
Ok, so for the dumberer of us out there, what is the difference between doing this and doing the HID kits offered by others? Are the others just bulbs without the projector or???

MustangMatt96GT
03-06-2012, 02:13 PM
I had found that I never needed or used the High Beams once the HIDS were installed... they were plenty bright.

MustangMatt96GT
03-06-2012, 02:15 PM
Ok, so for the dumberer of us out there, what is the difference between doing this and doing the HID kits offered by others? Are the others just bulbs without the projector or???

most of the ebay kits are just bulbs and ballast's ment to be put in your stock reflector headlights, which is a big no no...

The link I have in the write up is everything but head lamp housings to do a HID projector Retrofit. When you get a retro fit done it gives a clean cut of the light out put and does not blind drivers at all when they are aligned like a normal light bulb.

Hotrodtractor
03-06-2012, 02:16 PM
Ok, so for the dumberer of us out there, what is the difference between doing this and doing the HID kits offered by others? Are the others just bulbs without the projector or???

The "other" way is an HID bulb that has been re-based to fit into a Halogen housing - some people have made it work successfully, but most times the housings are too different and it causes the light to scatter uncontrollably - most notably in the "low beam" setting where you need to be able to control the light output to keep from blinding oncoming traffic. Some guys have had good luck installing HIDs into both halogen reflectors and halogen projector housings - but that is not the norm.

Hotrodtractor
03-06-2012, 02:20 PM
I had found that I never needed or used the High Beams once the HIDS were installed... they were plenty bright.

Interesting.... just how does that work - you have the cutoff so light doesn't get projected up too far (or out too far) - don't you use the high beams for distance out in the country while driving? I guess I can't even fathom not using my high beams and don't really understand how that is even possible or safe.

On Edit: I should also add that my Dmax is going to be lifted pretty good, so my "low beams" will be aimed down quite a bit to be safe for traffic.

MustangMatt96GT
03-06-2012, 02:52 PM
The only thing the HID high beams did for me was light up the signs that were up higher and farther away, not much more than that. The amount the little reflector shield moves isnt a whole lot.

03 tx pwr stroke
03-06-2012, 02:56 PM
The link I have in the write up is everything but head lamp housings to do a HID projector Retrofit. When you get a retro fit done it gives a clean cut of the light out put and does not blind drivers at all when they are aligned like a normal light bulb.

And this can be done in any headlight housing? I really like the look of these as well as the functionality. Doesn't look as "ricer" as most projectors I've seen for our trucks.

MustangMatt96GT
03-06-2012, 11:04 PM
For the most part, the SD head lamp is big enough to fit no issues. But some of the smaller head lamps have a fitment issue.

4 Wings
01-10-2014, 02:44 PM
Nice write up. We haven't seen any resistance value issues affecting the PCM that cause transmission failures with HID conversions. Resistance changes from LED light conversions have long been a major cause of transmission failures. Several TSB's have been published covering multiple issues from LED conversions. Even the LED instrument panel light conversations cause PCM strategy errors that result in erratic transmission and torque converter clutch operation resulting either in damage or failure. So far, properly done HID conversions haven't caused any of the problems or generated technical service bulletins like the LED conversions have.
I'm glad you mentioned Ebay, aka low quality products too! If you have a high performance vehicle: Ebay, discount and other low cost and low priced goods are the exact opposite of high performance products. Ebay is for businesses that can't afford a website with online ordering and sellers of used items - period!