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Headlight gap help.

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Old Feb 25, 2026 | 06:03 PM
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Headlight gap help.

Recently replaced my header panel and noticed that the headlight bezels no longer sit flush like they did before. I have attached some pictures, the green truck is mine and the bezels and the red one is how it is supposed to sit. Any ideas on what might be causing this? Or how to fix it. Any help would be appreciated!




 
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Old Feb 26, 2026 | 12:44 AM
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What is a header panel?
 
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Old Feb 26, 2026 | 12:48 AM
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Originally Posted by My4Fordtrucks
What is a header panel?
it is the plastic piece that goes in front of the core support and holds all of your headlights and grille.
 
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Old Feb 26, 2026 | 04:26 AM
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From: Mi'kma'ki
You have to draw in on the small 10mm? nuts, to suck that gap up.
 
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Old Feb 26, 2026 | 07:54 AM
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Your fender is dented, and more than likely the other metal parts are out of alignment as well.

What does your door gap look like?
 
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Old Feb 26, 2026 | 08:30 AM
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Originally Posted by wwhite
Your fender is dented, and more than likely the other metal parts are out of alignment as well.

What does your door gap look like?
door gap is perfect. I’ll take a picture of it later when I get back to my shop but everything is straight. The fender looks dented but it isn’t. Everything is straight up front.
 
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Old Feb 26, 2026 | 08:31 AM
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Originally Posted by Green5.8
door gap is perfect. I’ll take a picture of it later when I get back to my shop but everything is straight. The fender looks dented but it isn’t. Everything is straight up front.
also, didn’t have this issue until after I replaced the header panel.
 
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Old Feb 26, 2026 | 08:34 AM
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Originally Posted by Green5.8
it is the plastic piece that goes in front of the core support and holds all of your headlights and grille.
Thanks for clearing that up. See below…

Originally Posted by wwhite
Your fender is dented, and more than likely the other metal parts are out of alignment as well.

What does your door gap look like?
Agree. The metal panels have to be out out of alignment.
 
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Old Feb 26, 2026 | 03:05 PM
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Originally Posted by Green5.8
also, didn’t have this issue until after I replaced the header panel.
The 'header panel' is not correct then.
Compare with the old one.

Get a factory one from the junk yard.
More than likely poor quality aftermarket parts, just read a post with your same issue, ...your not the only one.
 

Last edited by wwhite; Feb 26, 2026 at 03:12 PM.
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Old Feb 28, 2026 | 10:01 PM
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Originally Posted by FORDF250HDXLT
You have to draw in on the small 10mm? nuts, to suck that gap up.
11mm
 
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