Looking over the sticky for the Aerostar, regarding the stock headlight upgrade, came across this:

"This is the harness I use, but similar harnesses can be purchased from other vendors as well. Upgraded Headlight Harness for 94 to 04 Ford with 9007 Bulbs.."

The link is dead. Could someone link an appropriate link for the correct harness for the above description? Or a name of the harness, model number of the harness? TIA, BRGDS,

patrick

ps. Would these work?
And just how to install. Maybe this all should be moved to under the sticky.

p.

 

Here's a harness that should work:

Putco® 239007HW - Nissan Pathfinder 2012 100W Heavy Duty Harness & Relay

Unfortunately, they don't state what gauge wiring they use, just "heavy".

There was a recent discussion about this:

https://www.ford-trucks.com/forums/1...cessories.html

My preference is 10 gauge wires, so I usually build my own.

 

that is the same PUTCO harness I used in my 1997 Aerostar but purchased from Amazon

 

to install the new harness, you remove the factory plugs from the rear of each headlight, then you run the harness from the passenger side to the driver's side, behind the grille, tied to the large factory harness already there, connect the new Blue plugs one to each headlight, and one plug to the factory harness, connect the Black Ground wire's ring terminal of the new harness to the body, on the passenger side, install the relays near the battery, then connect the two Red wire ring terminals directly to the battery's Positive/Red Terminal.

Follow the instructions on wiring the relays, but I think they already come pre-connected.

 

Perfect. Thanks all for the relevant info. At my age need all the brightness i can get driving down the road. (except from the oncoming cars...) I don't need to re-adjust the beam focus after installation of the new bulbs? Shouldn't think so...

p.

 

There are no new bulbs in the harness kit, so you shouldn't have to touch them. You should not have to adjust the beam, unless you actually replaced the bulbs as well, their positioning are off already, or you're so ham-fisted that you actually disturbed the housing while installing the harness.

The other impediment to good lighting is the housing itself; it uses plastic lenses that get foggy over time, and it has the generally poor distribution of the DOT mandated illumination pattern. There are polishing kits you can get for the lenses, but there's not much you can do about the poor pattern.

 

yes it is better to start with new headlamps and new bulbs if you want to realize the full improvement. New Headlamps are around $70.00 for the pair, better bulbs around $30.00 for the pair.

Let's say you spend $150.00 on all the parts including the harness and delivery, it's a good investment on Safety. The labor is on you, like they say, "a labor of love" ha ha

you will have to remove the grille and the chromed plastic bezels that contain the front Turn Signals, for which you will need a Torx bit unless the two torx screws have been replaced with regular phillips screws. And you need one day to do everything.

good opportunity to clean the turn signal bulbs and lenses which get cloudy or to replace them.

 

I just installed the in my 1995 Aerostar, and the ground lead for the passenger side headlight was a bit too short to reach the ground connection on the inside of the fender, so I had to splice in some more wire, solder it and heat shrink it. It's a relatively easy job otherwise, although in order to fish the passenger side plug across, I took off the plastic grille in front of the radiator, the passenger side headlight chrome bezel, and had to loosen both the top bracket for the washer fluid reservoir, and the upper right bolt of the radiator. I followed the route the existing headlight harness used, across in front of the radiator, and zip tied the new harness to the old one. I connected the +12V leads to the battery side of the solenoid, and used the space inside the driver's side fender near the battery to mount the relay bracket. There's a ground connection in that area I used for the driver's side headlight ground, and there was a pre-existing hole that saved me from having to drill a new one for the relay bracket. The plug removed from the driver's side headlight goes into the socket on the harness, and I throughly wrapped them with electrical tape to protect from water and ensure they don't come unplugged. It's all working now...