Well, finally got this done!

First off, Thanks to whoever that started the group buy for the newer style headlights with the HID retrofits. Kudos to Tony (TCM_GLX) that does this work. Excellent work, great service and very quick follow up!! 5* customer service.



Day View



Night View

After all the trouble I had in getting the headlights off the truck, I ended up taking it to a shop to finish what I started. Thanks to NorthwesternCowboy for the link to some excellent instructions!!
Link to Instructions

But, there are 2 issues that I wanted report and checking if others had experienced the same.

1. We had a very hard time getting them to aim in the right place. It is not done yet. When the headlights are flush mounted on the header panel, the "Low-beam" cut line was at ~12' from the ground (Almost at the top of a box truck) with the truck standing 25' awayl. We adjusted the screw on the housing to as low as it would let us and still the best we could bring it down was ~6-7' from the ground. I couldn't have driven it that way as these awesome bright lights would have blinded everyone The only way that we could bring the cut line down was to actually mount the headlights tilted forward/down. At the maximum tilt forward, the cut line is now just a little below the line of the headlights.

2. The light pattern is aligned a couple of degrees to the left, meaning towards oncoming traffic. I will try to adjust the headlight mounting some more to see if these can be corrected. But, just wanted to pick your brains to see if you could give me some more ideas of how to get these light aimed right.



This is what I was targeting on the final outcome of the beam pattern.


This is the current pattern that I have. This needs to be further adjusted. There is a lot of light that is being thrown on the oncoming traffic as well as towards the shoulder. Also there needs to be some rotational adjustment that needs to be done to make the top cutline be more horizontal.


Headlight is mounted at full forward tilt and not aligned with the body


Headlight is mounted at full forward tilt and not aligned with the body


Headlights are pointing slight left of where they should be.

 

This is my dilemma as well. I have researched a little but not much. My question has always been how much adjustment do you have post install. Did you upgrade to a 05 header panel or chop yours up? Once chopped is there a difference? or are the mounting points the same resulting in the same amount of adjustment. I love the newer style, but what good is it if I lose my adjustment....

 

There is minimal adjustment on the headlight housing for the beams. Most of the adjustment will come from how you mount the housings onto the header panel. I chopped off a whole bunch from my '00 header panel. If I have to do this again, I would rather get an '05 header panel, which I am seriously thinking of doing anyways. I have a feeling that the shop guy did not do the correct mounting and hence the beam is pointing outwards to oncoming traffic. I will work more on re-mounting the headlights over the weekend, but looking at the lousy weather here in NoVA this weekend, this work may get postponed.

 

Maybe I am missing something...why does this not appear to be a problem with the design of the retro vs anything else?
If you cannot retain the stock location/adjustment(within a couple *) it would seem to be like an issue with the lights, not anything else.
I didn't follow the buy, so I don't know the price, but I would assume they were not cheap, and if I dropped a decent chunk on a body part that was out of alignment and a safety issue, I think I'd be asking them to fix it.

 

The problem is it is also a retro install on a header panel that did not have those style of assemblies.

 

^^^What he said^^^

 

gotcha, was assuming the mod still left you with some measure of adjustment/secure mounting.
Looks like I'll be sticking with my higher output bulbs in stock housings for now.
Thanks!

 

Where you able to get this issue resolved?

 

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Took an alternate route. Sold that truck as-is and then bought another EX to start all over again

I just received the LED retrofit kit from The Retrofit Source last night. Looking for a backup set of headlights before I begin the retrofit. This time around, I already have installed the 05+ header panel in the back to avoid any cutting. Here's what the EX looks like for now.


The black one is the newer style header panel. The grey one was the stock panel on my '03

 

Is it just me or does the newer header panel with the stock grill leave more of a gap?

 

They do. There's some amount of adjustment possible, which I haven't done yet as the intent is to get a newer style grill and then do the adjustment.

 

Thank you for the pictures. I can see how you putting the retro fit lights in the mod'd older headliner would cause issues.

 

Just an FYI,

Are you keeping, or do you have the "03" bumper with the "05-07" support?
I just installed the "05-07" support, but wanted to keep my "01" bumper as it is brand new from Ford. Even at my bumpers' lowest setting, it was hitting the support. I ended up cutting off the bottom of the support, my "01" bumper fits fine now, and I'll just order another laser cut "05-07" Grill.

 

I am keeping my '03 bumper and grill for now while I finish a number of other higher priority projects. I have two thoughts, 1. Switch to a 2005-6 bumper or 2. Switch to a 2010-16 bumper - front & back. These depend on whether I can find a set in good condition at a reasonable price.

 

Great pictures. I emailed Tony and he said he go the lights fix for you? Im confused as to why the lights didnt work.