Front bumper...
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Senior User
Joined: May 2004
Posts: 159
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From: Lubbock, TX
Front bumper...
Well, I did search, and all I found was a thread about how brittle the *'s bumpers are.
I was changing a driver's side headlight this weekend (the pass side was done in a rush, about a month ago), and when I ever-so-lightly pressed down on the edge of the bumper, so I could use a screwwdriver to assist to removing the light bezel, the damn bumper virtually disentegrated in my hand, slicing up one of my fingers along the way. After checking, the bumper is virtually covered in cracks all over the place.
So, this is going to become a 2-part question...
How do I remove the front bumper cover? What size are those torx head bolts on the front section?
Second, is there an easier way to remove the front light bezels? How difficult would it be to swap in 92+ composit lights, or even the light convo's for the sealed beams that you can buy from JC Whitney(http://www.jcwhitney.com/autoparts/P...?Ntt=headlight)? How difficult is it to get to the bulb from under the hood?
This is not MY van, but my wife's. Therefore, I do not have it available to me right now. Nor do I have my service manuals (i have the 2 main Ford FSM's.)
I was changing a driver's side headlight this weekend (the pass side was done in a rush, about a month ago), and when I ever-so-lightly pressed down on the edge of the bumper, so I could use a screwwdriver to assist to removing the light bezel, the damn bumper virtually disentegrated in my hand, slicing up one of my fingers along the way. After checking, the bumper is virtually covered in cracks all over the place.
So, this is going to become a 2-part question...
How do I remove the front bumper cover? What size are those torx head bolts on the front section?
Second, is there an easier way to remove the front light bezels? How difficult would it be to swap in 92+ composit lights, or even the light convo's for the sealed beams that you can buy from JC Whitney(http://www.jcwhitney.com/autoparts/P...?Ntt=headlight)? How difficult is it to get to the bulb from under the hood?
This is not MY van, but my wife's. Therefore, I do not have it available to me right now. Nor do I have my service manuals (i have the 2 main Ford FSM's.)
Thread Starter
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Senior User
Joined: May 2004
Posts: 159
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From: Lubbock, TX
What keeps them from working? I mean, is there a problem with the actual chassis assembly in the front to prevent it? If it's just a wiring issue, THAT I can overcome...run relayed wiring harnesses for high wattage lights. What type of bulb do the 92+ lights use? 9004?
What about the JC Whitney conversion kit I linked to?
And with the bumper, again, how difficult is it to remove? I'm going to need to find a replacement soon...
What about the JC Whitney conversion kit I linked to?
And with the bumper, again, how difficult is it to remove? I'm going to need to find a replacement soon...
Post Fiend
Joined: Apr 2005
Posts: 5,720
Likes: 5
From: Washington state
Aero's are dual wattage bulbs, put 9007 80w100w extreme brightness blue cast whites in my 96 from Whitney with relay 14 ga wiring, works great on those dark winter nights with rain black roads and deer/elk jumping out to commit hari kari.
a pain to change bulbs though, have to remove battery and air filter box or rip meat off back of hands.
i used the replacement glass headlights on another older vehicle that take the H3 dual watt 80w100w halogen bulbs, put in relay large gauge wiring, worked great. replacement H3 last about same as top brand halogen headlights.
front bumper, front three torx will come out with 3/16 hex bit, also same bit on bottom four screw/bolts.
use penetrant oil on four bottom screws day prior to removing bumper, reach thru fender opening, heavy rust. just a decorative plastic cover, real bumper? underneath.
Rock Auto has new bumpers, lower price than Motorcraft
a pain to change bulbs though, have to remove battery and air filter box or rip meat off back of hands.
i used the replacement glass headlights on another older vehicle that take the H3 dual watt 80w100w halogen bulbs, put in relay large gauge wiring, worked great. replacement H3 last about same as top brand halogen headlights.
front bumper, front three torx will come out with 3/16 hex bit, also same bit on bottom four screw/bolts.
use penetrant oil on four bottom screws day prior to removing bumper, reach thru fender opening, heavy rust. just a decorative plastic cover, real bumper? underneath.
Rock Auto has new bumpers, lower price than Motorcraft
Last edited by 96_4wdr; Aug 23, 2005 at 02:42 PM.
Thread Starter
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Senior User
Joined: May 2004
Posts: 159
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From: Lubbock, TX
I can buy a brand new, aftermarket cover locally for $156...plus tax - no shipping (tax is cheaper than shipping for such a large package)
Does anyone know of any physical problems upgrading to the newer headlight assemblies? Will they physically fit into the van? If so - I imagine they will - I can rewire the van, using relays and 12-10G wire...
Headlight relays like that also same a lot of internal stress on the OEM light switch, reducing the amount of voltage required to flow through it.
Just a thought...
Thanks for the info, 96_fwdr
Does anyone know of any physical problems upgrading to the newer headlight assemblies? Will they physically fit into the van? If so - I imagine they will - I can rewire the van, using relays and 12-10G wire...
Headlight relays like that also same a lot of internal stress on the OEM light switch, reducing the amount of voltage required to flow through it.
Just a thought...
Thanks for the info, 96_fwdr
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Post Fiend
Joined: Apr 2005
Posts: 5,720
Likes: 5
From: Washington state
try local junke yard, see if they will let you try newer assembly in your Aero on a return basis.
14 ga is rated for 15 amp, even the 80w100w bulbs only draw 8-10 amps max, easier to run 14 ga, get the superflex high strand count, will lay flat anywhere.
RockAuto $68.79 primer FO100124 shipping <$30.
take an extra 5% discount with this code
264757253612
</PRE>use the $60 diff. with local price for end of summer van beer work party, will buy lots of washing, waxing, spark plug changing labor.
don't know any of the local Aero owner who have converted over to newer style headlights. most original Aero owners are ageing now and not into the mod's thing any longer.
see lots of butt ugly Scion's and Elements with strange aftermarket tail/brake light assembles that look they came off a Klingon Bird of Prey, 8" exhaust pipe tips, underbody flashing neon lights, and engines/exhausts that sound like a Husquavarna chain saw on Viagra.
14 ga is rated for 15 amp, even the 80w100w bulbs only draw 8-10 amps max, easier to run 14 ga, get the superflex high strand count, will lay flat anywhere.
RockAuto $68.79 primer FO100124 shipping <$30.
take an extra 5% discount with this code
264757253612
</PRE>use the $60 diff. with local price for end of summer van beer work party, will buy lots of washing, waxing, spark plug changing labor.
don't know any of the local Aero owner who have converted over to newer style headlights. most original Aero owners are ageing now and not into the mod's thing any longer.
see lots of butt ugly Scion's and Elements with strange aftermarket tail/brake light assembles that look they came off a Klingon Bird of Prey, 8" exhaust pipe tips, underbody flashing neon lights, and engines/exhausts that sound like a Husquavarna chain saw on Viagra.
Last edited by 96_4wdr; Aug 24, 2005 at 01:05 PM.
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Thread Starter
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Senior User
Joined: May 2004
Posts: 159
Likes: 0
From: Lubbock, TX
Yeah, I know. I'm looking at it more of a bumper/labor saving tactic than a mod. Getting the 85-91 headlight bezels out to change bulbs is a chore in itself. And I know that 14G should be sufficient, but I already have a surplus of 10 & 12G wires from various other projects...
I hadn't priced Rock's bumper...I'll have to look into that...that would definately be cheaper...
I hadn't priced Rock's bumper...I'll have to look into that...that would definately be cheaper...
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