I've got my SilverStar 9008's ready to install and have found that the two lower 3/32" bolts seem to be a doozy to remove so I can get the original bulbs out.

Inserting a thin extension from the front might be the answer but I don't have one that slender and long. The available space between the fascia and headlight is pretty narrow. I can get to them from underneath but one is a genuine bitch with partial turns with a box wrench in such a confined area.
Well I feel better now that I've whined awhile

Anyone out there have a simple answers ?

 

gear wrench?

 

First thing is if you are replacing just the bulbs why do you have to take the whole light out?
Second the screws are metric.
If you need to take the light out remove the grill first then take the 4 screws out. A 1/4" socket and long extension will get to the bottom 2 screws.

 

1. In reading the owner's manual, it says you need to pull out the whole damn light assembly! For what it's worth, I have busted enuff clips/tabs etc. on vehicles doing what I thought made sense and am not so inclined with this new beast.
If I can R&R the headlight bulbs in place, please give me some pointers.

2. Don't presently have metrics that small...3/32" seems to wrap around those leetle buggers pretty well. Do you recall the metric size.
And yes, I wanted to pull the lower two from the front but the space between the headlights and fascia is damn tight. So for that job (if it's really necessary...see above), looks like I need a mighty thin 1/4" extension about 12-14" in length.

Thanks in advance for any amplifying details/shortcuts. The pool of experience on this forum is so useful.

 

Unless your truck is an XL, you should be able to just reach down behind the headlight assembly in the engine compartment, grab the big plastic nut with the wires in the middle, give it 1/4 turn and pull the bulb straight out.

Matt

 

Sorry if I came across badly. It's been a while since i've taken one of these trucks apart but I thought you could get to the bulbs from the engine compartment. If not I don't remember it being hard to get to the bottom 2 bolts. But after you have torn down several truck to a body in white and then totally put them back together things seem easy, especially when all I work on is Ford trucks at work.
I think you had a typo 3/32" is pretty small. 7/32" is close to 5.5mm and that's the size the screws should be, all though Ford likes to sneak in 5mm and 6mm for some reason.

 

I just used a thin extension on a wratchet. You can also take the socket for that size bolt and find a wide tip flat-head screwdriver that will 'fit' in the square drive opening on the socket and use a long screwdriver with the socket end on it.

I've done that also.

FYI its NOT easy to get the light out without removing the grill. BUT the grill is a piece of cake to remove. 4 bolts on the top of the grill (same size as the headlight bolts) remove those... let the grill lean forward, and with a long flat-driver there are 4 (maybe 5) metal flex tab clips...

with your flat-driver reach down between the back of the grill and the radiator frame and push the end of the driver between the metal tab and the frame and the clips will releaase.

With the grill out of the way the headlights come out WAY easier.

And a trick for getting the headlight bolt-screws back in. Use a magnetic 'retriever' get the bolt-screw positioned on the end of the magnetic tip and work the bolt-screw back to the position from the edge and you can get it inserted and about a half turn with the magnetic force. then put your driver with a socket on the end on it and tighter her up.

I probably made it all sound WAY harder than it really is. But I can get the grill and both headlights out in about 4 minutes. Same fot getting them back in.

 

I have done it both ways; taking light out (w/o removing grill) and reaching in and taking bulb out. The drivers side is a must for taking out the light unless you have friend with a mini hand.

I used a 1/4" 12" extension and the nut size is a std 7/32, same as the top 2 bolts. Reach up from under the fender, grab the extension and place it on the bolt. Back it them out and take the bolts with your hand from under the fender as they will drop and I lost one.

Not a big deal job. Slide the lights out the front by working it around the grill and the outside quarter panels. remeber don't touch the bulbs as the oil on your hands will blow the bulb once they get hot. Reverse the process to finish

Enjoy the bright lights! Two cocktail & one cigar job . . .

 

Your favorite beer is already iced down....drop by any time.....

 

Make it a bourbon! Your weather is probably better than ours right now. Be right over

 

Will get me a long thin extension and follow your good tips.

I replaced my original fog 9145's with SS 9005's yesterday and checked them out this evening---much brighter.

Next is running a clean look power lead up thru the instrument panel to the dash top mounted fuzz buster. All info to date says to just work the wraparound trim piece back using a broad flat blade. Since it would really bust my chops to visually screw up that high vis area, are you all in agreement with this method of removal? I am ready to do it if you guys concur.
Thanks

 

You know there's a power line available from under the dash behind the drivers side 'glove box' right?

 

Actually it is a cutomer access power lead, 10 amp, and on an '06 it is below the radio, up to the right of your "drivers glover box". Has a white tag on it label customer acces.

 

You guys are killen me with good info!
Now howzabout an answer to my dash trim removal question....

 

Where is the question? All you need to do is pop it out as it is held in by spring clips. No need for a screw driver just start by ht edrivers door by easing it out by hand.

Put the drive shift all the way to the right and unhook the electric plug-ins for the power source, headlights, etc. Vola, it's out!