How to Install HID Headlights - Lighting Up The World

After scoring the ribs, we used a pair of vise grips to grab the aluminum rib and break it off. After doing the first headlight bucket, we found that keeping the vise grips as tight as possible when grabbing the aluminum makes the cleanest edge. If the aluminum is not breaking easily, run the razor knife over it again.

This is the finished product. It's not pretty, but it works and is not seen from any angle once everything is assembled. Before you put the vise grips and razor knife away, make sure the headlamp assembly fits without rubbing on any of the cut aluminum ribs.

Here's a tip: before attempting to install the new HIDs, install the screws in their respective holes to tap threads in the plastic housing. This will save a lot of aggravation during assembly since the screws have a tendency to go in at an angle. You can control the screws and install them straight into the housing when the housing is in your hands.

We found it much easier to install the top outer screws with the headlamp housing out of the way. There is no easy way to get on the screw to install it and turn it later. Once the screw is in place, put the housing up to it and start the screw. A couple of turns with a 10mm wrench is used to make sure the screw is started.

The inside screw can be installed and started by reaching around the headlamp bucket. We put some soft rags around the hood and fender to protect them from falling pieces and possibly rubbing the headlamp housing on the paint.

Once all the screws are started straight, they can be tightened up carefully. The screws cut into the plastic and hold good enough to break off the plastic mounting ears, so be careful. Watch the wrench during tightening. it can contact the fender easily and even when covered, damage can occur.

A piece of two-sided foam tape is provided to attach the ballast to the inner fender. The two-sided tape allows you to stick it into position, then screws are supplied to positively retain the ballast. The instructions warn you not to cover the serial number on the backside of the unit in case you need to order a replacement ballast.

Next we installed the screws to retain the ballast on the inner fender. The inner fender material is light plastic, so don't force the screws into position. The screws require light torque during tightening to prevent plastic damage.

The wiring is well explained in the directions. You'll find some of the new headlamp wire connectors have wires missing, which is normal. The new HID headlamps use ballasts to boost current so the OE lights require low current to trigger the HIDs.