3M number 39017 will take care of the yellowing. I would not advise going to a higher wattage bulb, I've seen the connector at the bulb melt because a customer had removed the 55/60w factory bulb and installed a 55/100w.

 

The heat alone from a 100w bulb would scare me off from putting them into a plastic lens. My IPF 7" lights (glass lens) came with 100w bulbs and they produce loads of heat I can feel come through the grill.

Taking care of a relatively expensive part to replace is a small price to pay.

 

my dim lights were caused by loose connections in the sockets which caused the plastic housing to partially melt and not make full contact between the male & female pins.

 

I can appreciate your desire for headlight housings that are not yellowed. I share your sentiment of having crystal clear headlight housings.

I dont know what wiring diagram you are looking at but Ford does not use a headlight relay in this generation of F-150.

With my experience switches, wiring connections and wiring looms tend to deteriorate as time passes. As these things deteriorate the voltage drop between the battery and the lights themselves will increase and the working voltage for the lights will drop.

The author of the article is right on when he claims that the voltage can degrade to such low voltage levels. You will also find that the wire guage used in the light circuit is not nearly heavy duty but only adequate (16 and 20 guage at the bulbs). If a person were to follow the basic idea in this article, to apply relays and use 12 guage wire in the new circuit then the voltage level would be a better than it ever was with the stock wiring and the headlights would be insured of good working voltage. This is of course assuming that an eletrically good circuit is implemented.

 

The reason they are still clear is because they are glass..not the plastic that these trucks use for the headlights. Also it is pretty simple to "fix" yellowed lenses with wetsanding..ive done a couple of vehicles that turned out good..not factory good but much better than before.

 

Lol, very true bobby! I've got derby cars in the back yard that have been sitting in the sun since the mid 70s, and they're headlights are crystal clear! Glass doesn't yellow because glass doesn't break down in the sun and weather like plastic does. Can you imagine the uproar if all the manufacturers went to lexan windows to save weight? lol you can't compare apples to oranges.

 

I have run the 80/100 w in my 03 for 3 yaers with no problems. The light they give off is night and day over stock. This is good for where i live there are alot of deer to hit so the extra light helps a ton.I also do alot of night driving.

 

Both the Owner's Guide FORD provided w/my '98 F150 & Haynes '97-'03 manual show a headlight relay is used "in this generation of F-150".

Have you got information that indicates FORD & Haynes published an error?

From your post it appears that your faith in the headlight wiring mods you recommend is 100% theoretical. Can I presume that you have neither: confirmed actual V losses or done the mods & confirmed V improvements?

My experience w/these kinds of simple electrical systems contradicts your gradual "tend to deteriorate as time passes" & "voltage drop ...will increase" experience. What I generally see is like the line from Bob Marley "Every day the bucket goes to the well, one day the bottom will drop out". IMO simple circuits work 100% for a very long time before any deterioration is measurable & when some component does deteriorate there is usually a rather rapid decline to nonfunctional or intermittent. Marginal connections tend to heat up & pop, reseat themselves, or vibrate one way or the other. Poor connections & conductors are easily traced by checking resistance.

The 9007ST is rated 65 W (V X A = W) at 13V that's merely 5 A. I seriously doubt there would be any measurable difference in V between the wire gauges in question in this app. IMO there would have to be a defect for the V to drop to "10-11V". I've had no apparent "voltage drop" issues, which would be obvious if it were true that OEM's "torturous path" resulted in only "10-11V". There is only so much V available, thicker wire can't increase it. I'd bet V at my 10 YO lights is equal to battery V on my digital meter.

 

Either of you guys confident enough to put your money where your mouth is? I could use some quick cash. Bet you my life savings they're plastic.

"Lol" all you like, I am. Its comical that you guys are so naive you believe I can't tell glass from plastic, also sad b/c you're so sure & so wrong about Club Wagon's "aero headlamps" which are "The original lenses on my 225K '92 E150" & standard on XLT & Chateau.

Now go back to "wetsanding".

 

Well if they are plastic, then i sincerly apologize, i wasnt trying to say you couldnt tell the difference between glass and plastic.
Its just that every E-series i have ever seen had glass headlights..

 

Yes, I have two versions of service manuals for my truck. The first is a Ford Motor Co. published large scale paperback electrical manual. The second is the widely available CD version of the Ford service manuals. Both of these electrical wiring diagrams support my statements of there being no headight relay routing battery power directly to the headlights.

You are correct in assuming that I have neither confirmed actual voltage losses nor have I performed any modifications in this circuit on my truck. This simply means that you and I are on the same level here.

My assertions in my previous post come from 27 years in electrical and electronics. 22 of those years in electrical troubleshooting of vehicular electrical systems. I also have design experience in wiring harness among other things. Have a good weekend.

 

Although its a bit late now to add qualifications to your statement, please be so kind as to acknowledge that FORD does indeed "use a headlight relay in this generation of F-150". Please confirm this based on the manuals you used.

If you'd like to "support" the comments made on the link you recommended please use your "27 years" experience to show us how the alleged "torturous path" actually reduces V to "10-11V" as claimed. I still believe these systems, working as designed, deliver the full V to headlights.

I didn't study diagrams to learn if full amps pass thru the dash switch as claimed, or confirm what function the headlight relay FORD uses actually has. Perhaps you could enlighten us?

 

Sorry, but by posting "if" you persist in "trying to say" I can't "tell the difference"! Your apology is as lacking & insincere, as is your lack of familiarity with the E-Series "aero headlamps" seen on every XLT & Chateau from '92-'07. Only base models & XL versions have glass sealed beam headlights.

IMO its virtually impossible that "every E-Series" you've "ever seen had glass headlights" since the plastic lens "aero headlamps" have been common & seen daily for over 15 years. Time to admit that you made a false assumption, never noticed what was right before your eyes & are simply wrong.

 

Ok, i admit i was wrong...for the second time..
Anyway i can honestly tell you that i havent seen/or ever remember seeing a E series with plastic headlights..not saying they dont exist, just that i havent seen them.
All the E series i have ever serviced had glass headlights, which is apparently due to them being base/XL models.. Also the E series that live around me are work trucks, which means they have glass headlights.
Also i have never seen or even heard of a Chateau or Club Wagon E series(also not saying they dont exist..just ive never seen one). Vans arent very popular were i live, except when used as work trucks.

 

OK, I can live w/that, you've never noticed E-Series "aero headlamps" used for 16+ years since they were introduced on 92's & "never seen or even heard of...Club Wagon". Perhaps the next time you'll consider taking the word for it from someone w/the ID Club Wagon? Pardon me for taking you to task, not only am I a Chateau fan, but my Dad's career was w/GE where Lexan was developed.

Just b/c you never noticed doesn't alter the fact that you probably can't drive across your town w/o passing several "aero" equipped vans in plain sight. Its not like the urban sprawl of Lee Cty/Ft Myers is the dark side of the Moon or anything. Econoline "aero" lights were also an option & are very common on conversions as well. They look & work much better than the old sealed beams. Still sure you "have never seen them" or did you presume they were glass?