I just replaced my 89 Aerostar with a 94 LX version. Love having the extra room! However, the headlamps on this puppy are baaad. It's like driving with two flashlights. A while ago someone posted resource for replacement headlamps, but the company only shows that fits through '92. Anyone know what changed on the '94 or if replacement 89-92 lamps would work?

 

Yes, I posted earlier that Pep Boys carries the "Kool-Vue" line, but I've been too busy to check it out (and relaly not that close by to me). If you have a Pep Boys nearby, let us know. I thought I saw it was up to the 1997 models.

The Pep Boys here didn't have it in stock and needed to special-order them.

It's actually the front plastic covers to the headlamps, that's become yellow and hazy.

Good luck.

 

In a pinch, you can cut a lot of the headlight "haze" with a rubbing compound. I do have a Pep Boys nearby, though, and will check out the headlights recommended in the second post.

 

I have a 95 areo and my headlights suck the big one too. So you say rubbing compound on the inside or outside, maybe both. To clear them up a bit. I know my friend sent out and got some clear performance lenses from some place in the states. But new lights were like upwards of 500 bucks canadian, too much for my blood, I guess a set of blue halogens might help a bit too eh, just a high performance bulb set. Still have to look into that one

Driving in the rain is like having no headlights at all

 

The blue halogens actually detract from the amount of light that it puts out (but looks cooler). Use rubbing compound to polish off the haze, then go over it with some cleaner wax after you buff off the rubbing compound, then finish wax. Yes, I do like overkill. It will still be a bit yellowish because of the plastic though. Sylvania has some Xtra brights (or something like that) bulbs that are supposed to be much brighter (3x according to package ) that I'm going to try some day.

I think the only real way to get enough light out of the aerostar is to get a set of round "off-road" lights, mount them in front of the grill, and aim them far enough down to avoid blinding other drivers.

 

Two remedies I can speak to, one I've used myself and one I've had recommended. The first is "NOVUS" plastic polishes. They have numeric values assigned, "3" for REALLY bad scratches, "2" for minimal scatching, and "1" for light scratches and/or polishing. I've successfully used the "1" stuff on all my plastic headlights after they develop "cateracts". The other solution is a "special used-car-dealer strength" polish, apparently sold on eBay, that works waaaaaaaay better still. I've seen the ad, it looks great AND they include the plastic gloves you need to protect your hands from whatever evil chemicals are in the stuff.

Two other quick thoughts... I learned that the non-OEM replacement headlights will only stay clear about a year. They seem like a good value, but they ain't. I also learned that Ford SEEMS to have changed the composition of the plastic used in both new and replacement OEM headlamps, 'cause they really do SEEM to go a bit longer before they cloud over... With a grin I can say that I know these things because I've owned a LOT of Fords AND I've kept 'em way past "a few years".

DadVan

 

Last July I polished the headlight lenses with Meguiar's Plast-X plastic polish (or some similar name). I was shocked by how well it worked. Within 15 seconds per lens, 99% of the yellowing was gone and the lenses were almost like new. I actually called my wife out to have a look. Her opinion was "Gee, they look great. I'm going back inside."

I figured I would have to repolish the lenses once a month to keep the coat of polish fresh and the lenses clear. I was wrong. The lenses are starting to show a bit of yellow again, but I think it's due to the winter sand- & salt-blasting. I probably should have done them late in the fall, even though they still looked good then. Twice a year is probably going to be enough to keep them clear. At this rate the bottle will last for 20 years.

For the other Canadian members here, I bought the Meguiar's polish at Canadian Tire for about 9 bucks.

Highly recommended.

Cheers,
Eric

 

The plastic polish will clean up the surface haze on those plastic lenses, but with long term exposure to UV and heat, the plastic will turn yellow. You can't polish that out unfortunately.

There are a number of ways to premanently improve lighting performance:

1. Add a set of auxiliary driving lights. I think Hella makes a set that has a pattern that is a major improvement over the stock low beam pattern. They are shielded like the low beams, so they can be used at all times without offending oncoming drivers.

2. Replace the flushmount headlight bezels with the older style so you can use the older style 200 mm rectangular sealed beam lights. Then install Sylvania Extravision lights. Be warned that these lights have a higher wattage low beam than the stock lights (which is how they produce more light to begin with) so they will present a heavier load on the stock wiring. Use of relays with these, or any lights that draw more power, is highly recommended.

To take this a step further, try to get a European spec H4 light housing from a maker like Bosch. The optics are much better than anything US DOT spec'd, and the H4 bulbs are much more efficient. This will cost a bit more, but the results are well worth it.

You can go further yet, with custom HID replacements, but those will cost a lot more.

 

Restoring plastic lenses: I initially did this on my 86 Taurus, the car was not drivable at night and a pair of new headlamps were over $600. What you will need: Tools to remove the headlight assembly and a place to store bulbs. Oatly "ALL PURPOSE CEMENT" For PVC, ABS, CPVC [do not substitute] (From Hardware plumbing section); Two to three quarts of White vinegar, 99% rubbing alcohol (From Grocery). Blue masking tape, 600, 1000, & 2000 wet or dry sandpaper (From Auto paint supply or Hobby shop). 3M Plastic Polish Part No. 051131,AKA 39010 (From Napa). Old towel, polishing rag (old underwear works best)
Remove headlamps and store bulbs in a safe place, Clean outside head lamp with rubbing alcohol, with lens up, carefully coat seams with cement, keeping cement off lens, set headlamps aside and let dry overnight, with lens up, (Old small boxes will help) The next morning mix up a solution of half Vinegar half hot water, not over 140F. set head lamps lens down and pour in solution till full, check for leaks. Repair as needed. Let set for a day in a warm place. Pour out solution slouching it around. Dry headlamps for a day in a warm place. (Continued below)

 

Find the DOT numbers on the headlight lenses and tape them over, You do not want to remove the numbers or the **** on the lenses! Soak sand paper in warm water for at least 10 minutes. Polish the lenses with the sandpaper starting with 600 grit and finishing with 2000 grit, keeping the sand paper wet. Remove the tape and polish the lenses with the 3M polishing compound. Reinstall the lenses, clean the bulbs with the alcohol and reinstall them in the headlamp without touching the bulb glass area. You may want to buy replacement "O" rings for the lamps. Tips: You can do your sanding and polishing while waiting for the lamps to dry on the inside. A tiny, tiny bit of alcohol inside the lamp assembly may speed the drying. In some states it is illegal to drive any time without headlamps including during the day.

 

I appreciate all your help, and was wondering if you have a line on the Euro spec lights. I tried Altezza, but they say that after 1991 it changed and a retrofit didn't work. I'm willing to pay to get more light -- even after I polished the lenses it's still nowhere close to what my friends get with their Chevys (I know -- the "C" word), and lack of light, plus those ugly rear light covers, or the only main complaints I have about my baby now.

 

Are you sure you don't have crud on the inside of the light, the Taurus Headlamps leaked moisture in, the sun caused brown algae to grow, and the lamps baked it on making the lamps look as hazy on the inside as the outside. The 94 Aero Headlamps were pretty clean inside, but had a little dirt on the insides when I cleaned them. If you get them cleaned up you can go to a brighter bulb.

 

I'm not sure -- I'll try taking them apart this weekend, but the light is so dim that I'm not feeling hopeful. Sorry to sound lame - but it's great getting help from you guys. What would be the brightest type of bulb I could use in the stock lamps? I'd like to only take them apart once, so I thought I'd go get the brightest bulbs I can use and try putting the stock lights back together once. Thanks!

 

Silverstars are nice, but they also make a HO that is half the price, but I have tried neither in the Aerostar

 

Guys,

A few years ago I sprung for PIAA 9007 bulbs and they made a big difference. I understand that the "newer model" Japanese-made bulbs are just as good and a lot less expensive. The only thing I'd be careful of is ensuring you get 55/65 watt bulbs, nothing that's higher in current draw than stock. The wiring harness can and will be damaged by using anything "stronger".

DadVan