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Even with the 05 header panel I had to trim the drivers side core support behind it to clear my 07 Harley lights. If I did it again (on a truck with a good header panel; mine was cracked anyway) I'd probably keep the 04 panel.
If you only want to use a CUT '05 grille, you don't need to do anything
If you want to use a full size '05 grille, you'll need to replace the header panel, bumper valance and bumper pad as well (I guess you could lower your bumper but that would be fugly.
If you want to replace the lights along with it you'll either need to cut up your header panel with a dremel OR use an '05 header panel
If you buy a new/used header panel do yourself a favor and go OEM not aftermarket.
Even with the 05 header panel I had to trim the drivers side core support behind it to clear my 07 Harley lights. If I did it again (on a truck with a good header panel; mine was cracked anyway) I'd probably keep the 04 panel.
Heck if I know! I read a billion threads on the conversion and didn't see anything about it. I had to cut the right angle plugs for the marker lights off and swap them for straight ones and that made the passenger side fit. I first trimmed the header panel on the drivers side thinking that was where it was rubbing but I ended up having to trim a few inches off the actual core support before even the straight light marker plug would fit. The lights were aftermarket ones but the back of them looks similar if not identical to the oem ones I've seen in some other write ups.
Good to know. I plan on doing the 05 grille & header panel with Harley lights as well. I'm just not worried about the bumper, as I plan to build an offroad bumper, and I'll just match it to the grille.