How did you remove the front lens of the headlight. I have an idea for my 06 that would require removing the front lens. Anyone know if its possible on the 06's?
Craig
In short, you need to remove the entire headlight assembly from the truck and then heat it up in an oven (gas or electric, NOT microwave!! ) set at no more then 160* to 180* for about about 20 minutes, but, and this is VERY important, you do NOT want to let your wife see you doing it !! Also VERY important, you do NOT want the headlight assembly getting TOO hot. Anything much over 200* will be too hot... . the goal is simply to heat the butyl rubber sealant that the factory uses to seal between the headlight lense to the body to the point where it softens enough to begin lifting the lense off the headlight body as you pry between the lense and the headlight with a flat screwdriver. If the lense does not pry off relatively easily, it is likely still not warm enough... put it back in for another 5 minutes while you have a beer and/or GENTLY turn up the oven ... remember the goal is hot but not TOO hot... go for that 160* to 180* .
When prying, set the headlight on a rag/towel and pry slowly and carefully around the edge where the lense meets the body. On my 2005, there were a few places on the housing and lense that had interlocking tabs and these need to be pryed up in addition to prying around the circumgrence of the lense. I used both a flat screwdricer as well as a hard plastic "body panel remover" pry par. Do be slightly careful as to how hard you pry, because you can put small chips in the edge and probably even crack it if you are not feeling for the release of the butyl rubber sealant. The trick is to FEEL for the release of the butyl rubber... if the headlight is not opening as you pry, it likely needs to be a little hotter.
ALSO, know that when the sealant is hot/warm it is also STICKY AND STRINGY!!!
As you pull the headlight apart... be careful NOT to let it drip down on your wife's favorite casserole dish, the inside of the headlight lense, and even MORE importantly, do not get ANY of it on the chromed reflector inside the headight housing, beacause then you won't be able to clean it off without scratching or removing the chrome!!! (don't ask me how I know that!! )
Ok that about sums up taking it apart... Putting them back together is till another story. If you want, there is PLENTY more information on this process, as well other headlight modifications at HiDplanet : The Official Automotive Lighting Forum - The Buzz
If you visit the forums, you also get to see what and how other people are doing to get more light from their oem headlights. . it is an intersting AND informative website. .
So, after all that, youve got me curious-- what are you planning on doing once you take em apart... . ??