I did this install today after much research. Once I had the car in the shop, I had the most difficulty figuring out WHAT to cut. Hopefully these photos will help you. This is not meant to be a complete guide, but you can find more information regrading the install here:

Installing 05-06 headlamps on a 99-04 SD



This is a view of the driver headlamp. The headlight is attached by a pressure fit. I removed it by using a pry bar to pop it loose.


Below the signal lamps you will find two screws, remove them and remove the turn signal assembly.


This is a top view of the passenger headlight. The redline indicates the path I used to remove the headboard material. It doesn't need to be exact, but this should give you a good idea.


This is a angle view of the passenger headlight with the headboard material cut away.


This is a angle view of the passenger headlight with the headboard material cut away. The redline indicates the path I used to remove the headboard material. It doesn't need to be exact, but this should give you a good idea. The shaded red box indicates the location of the pressure fit that the 2000 headlight attached to. Remove this, it will interfere with the new headlight assembly.


Front view of left headlight area with all material removed. NOTE I did not picture the removal of the splash liner that sits directly below the turn signal assembly. I removed this completely.


comparison of old vs new headlights


what to expect!

 

NICEEEEE good writeup.. Did you do anything to touch on the alignment of them?

Reps sent

 

Not yet, I need to do a search on how to do it :P I havent looked closely either...I wanted to go home

 

The adjustment looks likes a torx bit sticking up out of the assembly.

You can turn it with a 5/32" 6 point socket.

 

thanks man

 

Are the gaps on top of the headlights just because the hood isn't shut all the way??

 

because I haven't trimmed the grille yet, it was just a test fitment. another day, another project

 

Gotcha. Looks nice

 

Great little write up, reps to you!

 

Nice job and write up. Pictures are always very helpful for me.