2nd Gen Non-Engine/Transmission How to remove stock headlights???

[RobG]

I got my Sport headlights today from Mark Rogers, and the Brite Box conversion kit from Geno's, and I'm ready to install everything.



Now I can't figure out how to get the darn headlights out. I removed the three 10mm bolts that hold them in, and popped them loose. The problem is that there isn't enough space to get the entire headlight assy out without removing the bumper.



And even if I DID manage to get them out, since the Sport headlights are basically the same shape, I don't see how I'd get them back in without removing the bumper.



So... any tips?



Thanks!



Rob

 

[Bob Wagner]

service manuel page 8L-15



sounds very simple, no mention of bumper removal.

 

[RobG]

That's real helpful, Bob. I don't have a service manual. If I did, I would have looked in it.



*sigh*



Rob

 

[Bob Wagner]

I could fax you the page if you like

 

[jsimpson]

Take the top trim off the bumper. Then remove the two screws from the front and the one screw from inside the fender. Then wiggle it out! Of course everything's easier with the bumper emoved.

 

[RobG]

Many thanks to Bob Wagner for faxing me that page from the service manual! It confirmed what I suspected might work.



Basically, you remove the turn signal lens first (comes off with one philips screw), and then you use a flat-blade screwdriver to pop off the little metal clips that hold the alignment screws in place. There are three -- two on top and one on the bottom. With that done, the headlight lens comes out just fine. Then you can slide the black plastic housing out.



Then the new lights go in the same way the old ones came out. The Brite Box conversion kit made things beyond simple. Stick the box itself into an open location, and plug the stock headlight harness into it. Then plug the two connectors from it into the appropriate light bulbs. On the other side, use the included harness to plug into the factory single plug, and that gives you the two plugs needed for the new headlight.



Reassemble everything, and you're done! Now all I have to do is aim 'em.



Darn easy.



Rob

 

[Cooker]

What exactly is the Brite Box conversion kit?



Thanks,

Ryan

 

[RobG]

It's a Brite Box (the thing that makes the lowbeams stay on when the high beams come on) that is modified to allow easy conversion from standard headlights to the quad headlights.



Rob

 

[Cooker]

Sorry Rob, your last post answered my question. We must have been typing at the same time.



I am familiar with the brite-box, but not the conversion kit. Basically it is designed to help facilitate the install of sport headlights in a non sport truck right?



I was thinking about this myself. I found a way to get it done easily or so I thought, but the conversion kit sound just as easy or easier. Is the price the same as the regular BB? It is wired with heavier gauge wiring than the factory headlights? Do you have to wire it to a power source also? Or is the only thing you do is plug it in?



Thanks for the info,

Ryan

 

[RobG]

The conversion version of the Brite Box is $165 (compared to $100). They tell me you can do it all yourself for $10, but since nobody had posted a parts list or where specifically to find the various plugs, I decided to just spend the money and get the conversion kit. It made things waaaay easier.



The wiring seems to be reasonably heavy-duty, although it just plugs into the existing wiring. The only other connector to hook up is a ground wire from the Brite Box to the negative battery cable.



Now all I have to do is get some better fog lights and I'll be in reallly good shape...



Rob

 

[Justbeamn]

RobG, I was under the impression that there was cutting involved to mate sport headlights to a non sport truck. Can you clarify this for me. Is this only for new model trucks? If I can ask what was the ballpark price for the headlights?



Thanks

Devon

 

[jsimpson]

Late model trucks require no cutting. My 94 DID require cutting.

 

[RobG]

2000+ trucks don't require fender cutting. Anything prior does.



The lights were $240 shipped (to me, in CA, from wherever he is) from Mark Rogers... not sure if he has any left or not. That included bulbs.



I played with the aiming of the lights a little and went for a drive. It'll take a while to figure out how to get 'em just right. The lighting pattern is very noticeably different than the stockers. It's much more spread-out rather than two spot-beams on the road ahead of you. The light quality is also brighter/whiter.



Rob

 

[D96ram1]

A rock hit and cracked mine.



I took my bumper off i thought it was easier.

But i don't think you have to remove it.

 

[Bob Wagner]

for patriot

Happy President's Day

 

[The patriot]

Thanks Bob.

 

[JOENS]

Sport Headlights

RobG,



I would like to have the contact information for the purchase of the sport headlights. Are these OEM lights or replacements? Do you know who makes them?



Thanks

 

[Eric Lee]

Unbuckle the clips

Thanks for the posts guys. I was looking at my bumper bolts too - even sprayed a little WD on everything getting ready for the dismount. Figured I'd come in and check our site.



Unbuckle the 3 little clips... ... . easy does it... ... ... wave the 10mm socket... ... . twist of the wrist... ... ... revolution of the brain... ..... and you're done.



I have a book but haven't opened it much since I joined TDR. And I know I'd still be out there cussin' the bumper if I didn't have TDR for reference.



- Eric

 

[swhalen]

This is a timely thread for me. Call me a dummy, but i can't for the life of me figure out how to get a headlamp housing out. I successfully removed the side markers as per the manual. However, the amual then states that I should remove screws holding the top of the headlamp module to the radiator closure panel. Then, from behind the bumper I should remove the screws holding the bottom of the headlamp module to the radiator closure panel. Ican't find any screws except the two that adjust the side to side and up and down position of the beam. What am I missing? Meanwhile, I have about 2 inces of water in one headlamp! thanks for any help. steve whalen

 

[Eric Lee]

Steve - This thread started out as



'How to remove stock (SPORT)headlights???'



and wandered into



'How to remove stock (Non-SPORT) headlights (and then install SPORT headlights)???



Which headlights does your truck have?



-Eric