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.