Time for me to chime in....as I have tried a few different options in my '07 expy as I was super unsatisfied with the light output on Hi beams!

I tried:
-Silverstar Nighthawks bulbs: decent light on low, but still crappy on high beams.
-PIAA Extreme White bulbs: the blue tint of the lens made the colors wash out on the road...especially the bambi's!

And then, I tried an aftermarket HID kit that went in the reflector housing. (I can hear the grumblings now... ...) I'd like to point out that they were actually not as glaring as you would think (atleast for the Expedition! I agree that other kits are awful). I aimed the lights into the proper position and tested the glare out by having my wife drive the truck while I drove the van...even had a friend do the same and it was concluded that there was, luckily, no glare. BUT! The light being reflected to the ground was horrible. My night vision was completely ruined because of how much stray light was being reflected onto the pavement right in-front of the truck. When I went to Hi Beams, it was still just as bad as before. I concluded that it was the crappy reflector design.

Would I recommend the HID upgrade: HELLS NO! The reflector is not designed for the high intensity of the light! The bulbs ARE the exact same size, but clearly the light output is not.

And here was the next step….and start of an epic fail!!!!

I ordered up a set of Eagle Eyes Halo/Angel Eye Projector headlights…these were about $300 for the pair. The original bulbs in them were Halogens with separate Hi and Lo Beam bulbs (H1 and H7). The way the wiring harness splits the leads, when the Hi Beams are selected, the Lo beams go out…. Not bad for Halogen, but totally scary when I put the HID bulbs in!!!

The other major concern was the beam pattern of the projector. There was no light going to the sides because of an even crappier design! Here is a link to my album showing this mod:

Ford Truck Enthusiasts Forums - freerider's Album: Projector Headlight Assembley with Angel Eyes - FAIL

The lights look very cool, and are OK in the city and decently lit areas. But on the Highway, in the middle of Timbuktu, THESE ARE A MOJOR SAFETY CONCERN! DO NOT BUY!!!!

I am currently awaiting a “real” set of projectors from The Retrofit Source which will actually mount in my existing OEM reflectors. These projectors and HID’s are the same as from Lexus and BWM and will provide DOT approved light! The only hinge is that I have to remove the lens cover from the OEM assembly and then get it back on… there are tons of write up on how to do it and it is the only safe modification I would recommend.

 

Have you completed the retrofit with the new glass lenses? How did it go? I too have the same headlight assemblies and I'd like to replace the lenses from the retrofit source. Is there a worthwhile improvement? Did you really have to remove the outer clear assembly cover to access the lens? I thought you could pull the projector out from the back side. Also, what diameter are the lenses you ordered? 2.5" or 3"?

 

I have finally ordered the kit...went with the 2" lenses but wishing I had the 3" ones now! From what I have read, you have to place the housings in the oven no matter which kit you go with in order to get the projectors and shrouds in place. The Mini's allow you to do the retrofit with out any cutting of the inner reflector. I went with the FX-R 3.5 Kit... It's going to be a while before I can tackle this retofit but I will post pics and a write up after I am done!

Go with the 3" if you can! They look pretty rad!!! Good Luck!

 

Ah OK I understand. I thought you were simply replacing the lenses from Eagle Eye to one of the retrofit offerings. I now see that you are replacing the entire projector system and will need to modify the headlight assembly accordingly.

 

I know this is an old thread but wanted let others know I had the same problems seeing at night and in wet weather with this same model light on my 01 ex.
Also they only had up and down adjustment and no side to side which is stupid.

I am replacing them with a 02-04 OEM replacement aftermarket. Funny thing is that they are made by Eagle Eyes also but maybe they're are going to be OK since they were a copy of the OEM. They never mention the maker where I bought them.