Reply
 
Thread Tools Display Modes
 
Old 05-08-2013, 09:50 AM   #1
Senior Member
 
ANZAC's Avatar
 
Join Date: May 2011
Posts: 1,005
Headlight Upgrade 1999-2007

The cheapest and easiest way to get better headlights is to upgrade to the so called "lo series" headlight mounts and put in halogen eCode lights and higher wattage bulbs, with a relay system and heavier duty wiring of course. The eCode lights from Europe are optically very good and have a LHD beam pattern. US versions (the 6054) are terrible, and the stock aero plastic lights (with 9007 bulbs) are even worse.

I did this mod to my 1999 cargo van, and then transferred it to my SMB when I got it.

Ford parts you need:

- "lo-series" headlamp backing panel (this is the big black plastic panel that runs the full width of the front and is behind the radiator grille and headlamps) I got mine from a wrecker. E150-350 all the same.
- "lo-series" headlight buckets and associated adjustment screws/springs. These are expensive to buy new, better to hit up a wrecking yard.
- "lo-series" headlight surrounds to match your grille. There are two color schemes (all black and platinum trimmed). These can be bought cheaply online but beware the chinese versions. I bought new OEM Ford from Ford Parts Giant. While I was there I got rid of my rusty billet grille and got the matching all black Ford grille.

Headlight and Wiring Parts

I got everything from Daniel Stern Lighting. I've been buying from Daniel since 1995 and he is an expert on lighting and only sells top quality products.

http://www.danielsternlighting.com/prod ... ducts.html

- headlamps: qty 2 Cibie or Bosch eCode H4 200mm x 142mm (drop in 6054 replacement)
- bulbs: I used qty 2 Narva 65/70W
- custom Relay Harness for E350

You can either make this harness yourself or get one from Daniel Stern. He sells a kit RIK-H4R, but he will also get the harness made up, which was an easier option, great quality.
- 9007 female input connector (to control relays from one of the existing headlamp plugs)
- H4/6054 connectors for new headlights
- 2 relays (SPST maybe with two output lugs?)
- wire, looks like maybe 12 gauge

Basically this harness has three sets of connections. Input wires to power both relays, using a connector to plug into the existing 9007 headlight plug. Power wire which goes to to alternator (I use the alternator fuse bus bar box). Output wires that go to each headlamp, with H4/6054 connectors on each. Obviously the run to the RH light is long-ish. I mounted the relays on the radiator support near the LH headlight.

I will update the thread later with Ford part numbers.

Attached Thumbnails
closeup.jpg  
__________________

__________________
Sportsmobile-less.

"A job worth doing is worth doing at least twice."
ANZAC is offline   Reply With Quote
Old 05-08-2013, 02:41 PM   #2
Senior Member
 
Abitibi's Avatar
 
Join Date: Nov 2012
Location: Vancouver, BC
Posts: 594
Headlight Upgrade 1999-2007

Good post.

I have your style of headlight housing (commercial vehicle?) on my ambulance so I guess I'm already 1/2 way there? If the bulbs you're using was there a need to upgrade the wiring? I would have thought to be needed only with higher wattage bulbs (90+)
I'll be following your post and might hit you with questions down the road.

Cheers
Mr. D
__________________

__________________
2001 E350 AmbuLand
1965 Econoline Travelwagon
1969 Econoline popup camper
1970 Econoline popup camper
A few bicycles...and sandals ;)
Abitibi is offline   Reply With Quote
Old 05-08-2013, 05:22 PM   #3
Senior Member
 
ANZAC's Avatar
 
Join Date: May 2011
Posts: 1,005
Re: Headlight Upgrade 1999-2007

Quote:
Originally Posted by Abitibi
I have your style of headlight housing (commercial vehicle?) on my ambulance so I guess I'm already 1/2 way there? If the bulbs you're using was there a need to upgrade the wiring? I would have thought to be needed only with higher wattage bulbs (90+)
I'll be following your post and might hit you with questions down the road.
Yes, you need the upgraded wiring harness. Two reasons: 1. the voltage drop across the thin wires means the lights will be dimmer with stock wiring, 2. higher current draw means you could cause a Car-B-Q (fire).

So, by going to 2 relays and thicker wire, you're greatly reducing the voltage drop and greatly increasing the current carrying capacity.
__________________
Sportsmobile-less.

"A job worth doing is worth doing at least twice."
ANZAC is offline   Reply With Quote
Old 05-10-2013, 01:11 PM   #4
Senior Member
 
Join Date: Apr 2008
Posts: 192
Re: Headlight Upgrade 1999-2007

I did exactly what you have done and sourced through Daniel. So I too can endorse that this is the only way to improve the lighting of these trucks. especially with a pair of driving lights to augment on low beam.
__________________
Hanging Out
vlamgat is offline   Reply With Quote
Old 05-10-2013, 02:40 PM   #5
Senior Member
 
ANZAC's Avatar
 
Join Date: May 2011
Posts: 1,005
Re: Headlight Upgrade 1999-2007

Quote:
Originally Posted by vlamgat
I did exactly what you have done and sourced through Daniel. So I too can endorse that this is the only way to improve the lighting of these trucks. especially with a pair of driving lights to augment on low beam.
Awesome!!

Forgot to say this is a about a 2 beer job, in terms of time it takes to get it done.
__________________
Sportsmobile-less.

"A job worth doing is worth doing at least twice."
ANZAC is offline   Reply With Quote
Old 08-06-2013, 09:03 PM   #6
Member
 
Join Date: Jun 2013
Posts: 45
Re: Headlight Upgrade 1999-2007

Lo series headlamp backing panel....what is this? Doesn't my van already have this?
Thanks!
Ajamboree1 is offline   Reply With Quote
Old 08-07-2013, 10:05 AM   #7
Senior Member
 
ANZAC's Avatar
 
Join Date: May 2011
Posts: 1,005
Re: Headlight Upgrade 1999-2007

Quote:
Originally Posted by Ajamboree1
Lo series headlamp backing panel....what is this? Doesn't my van already have this?
Thanks!
It is a full width piece of black plastic that the headlights mount to. It is easier to find this complete at a wrecker. The headlight buckets and adjusting screws, springs etc are expensive to buy new from Ford if I remember correctly. Easiest and cheapest way is a wrecker. There may be some differences in the plastic, I can't remember.
__________________
Sportsmobile-less.

"A job worth doing is worth doing at least twice."
ANZAC is offline   Reply With Quote
Old 08-07-2013, 11:54 AM   #8
Member
 
Join Date: Jun 2013
Posts: 45
Re: Headlight Upgrade 1999-2007

Sorry I'm still confused....why do I need to source these extra ford parts? Doesn't my 2003 van already have the plastic backing panel and adjustment screws etc?

Any one have the ford part numbers? Thanks!
Ajamboree1 is offline   Reply With Quote
Old 08-09-2013, 05:05 PM   #9
Senior Member
 
ANZAC's Avatar
 
Join Date: May 2011
Posts: 1,005
Re: Headlight Upgrade 1999-2007

Quote:
Originally Posted by Ajamboree1
Sorry I'm still confused....why do I need to source these extra ford parts? Doesn't my 2003 van already have the plastic backing panel and adjustment screws etc?

Any one have the ford part numbers? Thanks!
If you're trying to upgrade your headlights, do you have the plastic "aero" headlights like this?
The post tells you how to get rid of them, the mounting, adjustment screws etc are ALL different between headlight styles.



The "lo-series" headlights which are easier to upgrade to optically better lenses look like this:



You can find the part numbers at FordPartsGiant.com. Trust me, it is FAR cheaper to get the backing plate, screws and buckets from a wrecker.
__________________
Sportsmobile-less.

"A job worth doing is worth doing at least twice."
ANZAC is offline   Reply With Quote
Old 08-10-2013, 07:45 AM   #10
Member
 
Join Date: Jun 2013
Posts: 45
Re: Headlight Upgrade 1999-2007

Thanks Anzac! I do have the low series on my 03....sweet! Upgrading asap....!
__________________

Ajamboree1 is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

» Sportsmobile Registry

For Sale

Prior2

Vanny Devito

dick
Add your Sportsmobile
Powered by vBadvanced CMPS v3.2.3
Disclaimer:

This website is not affiliated with or endorsed by Sportsmobile SIP or any of its affiliates. This is an independent, unofficial site.


All times are GMT -6. The time now is 06:21 PM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
×