I have a question about the reflector body and lens in these H4 headlamp systems. I've seen some that have a double plastic lens. That the air space in the lens can leak where moisture and condensation fog up the lenses. Does this kit for Ford trucks have a double plastic lens?

On newer Ford vehicles these H4 headlamps were either optional or standard. I've see two leaky lenses. One on an Escort and another on a Windstar.

Since these kits are not cheap and I think if the lens leaks you have to replace the whole light can. Then the bulbs have to be handled with care...don't touch them!

On the Escort I was able to get the lens to come apart as the adhesive failed completely. Dried out the interior and then resealed the lens. That worked and the customer was happy.

On the Windstar the light cans are bigger, more styled to the body and replacement costs are high. This is where the sealed beam starts to make more sense or cents. Replacement is 9 bucks. I think the owner wants to replace H4 headlights with the sealed beam option. Looked up that year in the service manual and sealed beam was available on some vans.

Anyone know what I'm looking at to convert H4 back to sealed beams on a 97 Windstar? Remove the cans? Replace with a sealed beam frame? Change the connection plugs?

 

The lights I listed have absolutely nothing to do with or in common with the factory aero blended headlights. The Hellas are a glass lens with a metal backing.
Furthermore, Ford never used H4 lamps in anything in North America. They used 9000 series halogens.

Also the Windstar never used sealed beam headlights, you are thinking Aerostar Go back rethink what are you trying to say and try again in a new post.

 

I'm sorry, yeah the 9000 series Halogen. They plug into the back of the can or shell.

The double plastic lenses are poor design. I'm glad to hear that the Hellas have glass lenses. I might consider those for my truck.

I wouldn't have believed it myself but the Windstar manual does cover sealed beams. Says some models had sealed beams.

The owner of the van said they want sealed beams. Can't blame them when the cloudy plastic lenses are bad design. And replacements if can be found were running 100 bucks a side.

I had a question, not making a declaration. But thanks anyway.

 

I have never seen a Windstar with sealed beams. Post of copy of the manual. And the plastics can be polished back to new in a couple of mins with a power polisher.

 

The manual is not in my possession. Belongs to the owner. Might have an opportunity to post a pic at some point. Don't hold yer breath. But it would be in the Chilton's for 95 to 98 Windstars. No other models or years covered in that one.

 

Well, I can find no parts listing for sealed beams in the Ford parts catalogue for the Windstar now does any after market catalouge so I suspect he is confused with the Aerostar or Chiltons/Haynes was using generic pictuers from the Econoline or the Aerostar.

 

I'm not sure why they put a picture of a sealed beam headlight in that manual. And wrote a bit about it too. I wasn't reading that section except browsing at a glance because that wasn't the type of headlights on the rig obviously.

The owner mentioned it to me that they preferred the old sealed beam headlights and that the ones on their rig were giving them trouble. Both had water leaks. One with about a 1/4 to 1/2 cup of water in it. As an intermediate fix I drilled a hole in the double plastic lens cover to drain it. They're going to be replaced but the owners haven't made up their minds about the type. Maybe they read their manual and saw the example as I did too. I'm not even sure if I'll be doing the work. If I get some more details I'll post it. But really I've hijacked this thread so maybe not. I did look for headlight replacements too and I didn't find any sealed beam options but was mainly looking for the direct replacement. Looks like parts are available and 100 bucks should be enough for both sides including the new bulbs. I doubt the conversion to sealed beam would be much less so probably a moot point anyway.

 

See if they ever made a utility version for that van. I had a old Dodge Caravan. It had the plastic headlights, but I found out their utility version (the one without windows) had the old sealed beams. I actually converted mine over after the plastic ones fogged up. I had to get several pieces to do it, but they fit right in place. I don't know if Ford did this with some of their vans or not.

 

Aerostar Yes. Windstar No. The Windstar cargo still had the plastic aero lamps (see below pic). The stripper Windstar cargo's (no side or back glass in the body, Slider still had glass) are quite rare and IIRC was only available the first couple of model years, after that the cargo got all the same side glass as the rest of the Windstars. As for the headlamps, the style of the Windstar headlights and the dimensions of the opening in all practicality prevented the use of a sealed beam option.

 

Yea I saw the cargo van option. Probably the biggest difference was no seats in the cargo version.

This particular one is the passenger LX with the 3.0l. Nice little van. Drives and handles well for a mini van.

Not sure why the manual had a subtitle and a picture of a sealed beam. The manual does not cover Aerostar which does have sealed beams on all models. I'll find out eventually and post the purpose of it showing up there. Maybe it's there to show you what you don't have?

Does not indicate any other vehicles covered.

 

The Aerostar Originally had sealed beams, and later on went to aero headlights with sealed beams being retained on the cargo/base version for a few years afterwards.

 

The Aerostar Originally had sealed beams, and later on went to aero headlights with sealed beams being retained on the cargo/base version for a few years afterwards.