joshdhat
Member
- Joined
- March 25, 2013
- Messages
- 17
- Reaction score
- 0
- City, State
- Dallas, Tx
- Year, Model & Trim Level
- 13 Explorer Limited
Ok as promised, here is a complete how to guide for retroing the stock ds3 system to the much better ds2 setup.
i apologize i didnt take any pictures of the process or a before shot.
tools needed,
1) T20 torx bit, you will also need a smaller one forgot the size.
2) 7/32 socket
3) 1/2 socket
4) 7mm socket
5) 10mm Socket
6) Flat Head
7) Phillips
8) your preferred way of cutting and splicing wires
9) replacement ds2 projectors ( I used BI-XENON: HELLA EVOX-R)
10) replacement ds2 bulbs (D2S: OSRAM XENARC 66240 CBI)
11) replacement ballast (DENSO SLIM BALLASTS)
12) 5 pin relay and harness
13) re-sealant (OCI BUTYL RUBBER GLUE)
Step one,
You do not have to remove the bumper to remove the headlights but it does make it easier. remove all the 10mm bolts on the top along with the two pop tabs. then the 7/32 screws in the fender wells. once all the screws are out the bumper will pop forward allowing access to the two remaining headlight screws. one on the side 1/2" one in the front 10mm. if you want to take the bumper off there are several 5/16 screws on the bottom.
Step two,
Dissemble the headlights,
start on the bottom, there will be 2- t20 torxs screws on the bottom and one on the side. then remove the stock ballast, 4 7mm screws. unclip the connections. remove the running light and blinker. there is also a 7mm bolt on the back of the housing that needs to be removed.
repeat for other headlight.
Step three,
preheat oven to 250. then place headlight black side down in for 15 min.
then take a flat head and start to pry the lens apart. i was not able to separate them at one time. get as far as you can. then place them back in the over for an additional 10 min. then they should easily separate.
repeat for other side.
Step four,
this is where the smaller torx bit comes in. there will be 4 screws holding in the stock projector housing. remove them. there is a small clip on the high beam shroud unplug it. leave the wire on the stock bulb.
step 5,
assemble the new bulbs into the new projectors. place the new projectors into the headlights using the 4 torxs screws. remember that the cut off shield goes on the bottom. plug the factory connecter into the high beam shroud.
step 6
plug the new ballast into the new bulb. now the fun part starts. black wire off of ballast goes to the black wire inside the headlight. red wire goes to green wire inside headlight. orange wire is unused. i wedged the ballast in the base of the headlight. repeat for the other side.
step 7
place the BUTYL in the grove of the housing on the headlight. try to thin it out, if you do not thin it a little bit it will be extremely hard to reset the lens with the housing. once the BUTYL is applied place the housing in the oven at 210 for 7 min. then place the lens on the housing. apply good pressure to seal all the way around. repeat with other side.
step 8,
reassemble the stock ballast , blinkers and bottom bracket. the headlight is now finished.
step 9,
wiring
this is the way i wired mine. i taped the wire at the plug on the headlight. also tapped the driver side.
87= brown light blue toward headlight. which is the green wire inside the headlight.
i also ran a leg off of this to the passenger side to charge that headlight. i believe is also brown light blue. could be wrong. but is is in the same pin number as the drivers.
87A= unused
86= brown light blue toward the car.
85= ground/ black green
30= constant power/ red
use what ever method you like to wire and make splices and connections.
step 10,
once all the wiring is done and tested re-assemble your car.
step 11,
use the phillips tip to aim the headlights up and down.
i apologize i didnt take any pictures of the process or a before shot.
tools needed,
1) T20 torx bit, you will also need a smaller one forgot the size.
2) 7/32 socket
3) 1/2 socket
4) 7mm socket
5) 10mm Socket
6) Flat Head
7) Phillips
8) your preferred way of cutting and splicing wires
9) replacement ds2 projectors ( I used BI-XENON: HELLA EVOX-R)
10) replacement ds2 bulbs (D2S: OSRAM XENARC 66240 CBI)
11) replacement ballast (DENSO SLIM BALLASTS)
12) 5 pin relay and harness
13) re-sealant (OCI BUTYL RUBBER GLUE)
Step one,
You do not have to remove the bumper to remove the headlights but it does make it easier. remove all the 10mm bolts on the top along with the two pop tabs. then the 7/32 screws in the fender wells. once all the screws are out the bumper will pop forward allowing access to the two remaining headlight screws. one on the side 1/2" one in the front 10mm. if you want to take the bumper off there are several 5/16 screws on the bottom.
Step two,
Dissemble the headlights,
start on the bottom, there will be 2- t20 torxs screws on the bottom and one on the side. then remove the stock ballast, 4 7mm screws. unclip the connections. remove the running light and blinker. there is also a 7mm bolt on the back of the housing that needs to be removed.
repeat for other headlight.
Step three,
preheat oven to 250. then place headlight black side down in for 15 min.
then take a flat head and start to pry the lens apart. i was not able to separate them at one time. get as far as you can. then place them back in the over for an additional 10 min. then they should easily separate.
repeat for other side.
Step four,
this is where the smaller torx bit comes in. there will be 4 screws holding in the stock projector housing. remove them. there is a small clip on the high beam shroud unplug it. leave the wire on the stock bulb.
step 5,
assemble the new bulbs into the new projectors. place the new projectors into the headlights using the 4 torxs screws. remember that the cut off shield goes on the bottom. plug the factory connecter into the high beam shroud.
step 6
plug the new ballast into the new bulb. now the fun part starts. black wire off of ballast goes to the black wire inside the headlight. red wire goes to green wire inside headlight. orange wire is unused. i wedged the ballast in the base of the headlight. repeat for the other side.
step 7
place the BUTYL in the grove of the housing on the headlight. try to thin it out, if you do not thin it a little bit it will be extremely hard to reset the lens with the housing. once the BUTYL is applied place the housing in the oven at 210 for 7 min. then place the lens on the housing. apply good pressure to seal all the way around. repeat with other side.
step 8,
reassemble the stock ballast , blinkers and bottom bracket. the headlight is now finished.
step 9,
wiring
this is the way i wired mine. i taped the wire at the plug on the headlight. also tapped the driver side.
87= brown light blue toward headlight. which is the green wire inside the headlight.
i also ran a leg off of this to the passenger side to charge that headlight. i believe is also brown light blue. could be wrong. but is is in the same pin number as the drivers.
87A= unused
86= brown light blue toward the car.
85= ground/ black green
30= constant power/ red
use what ever method you like to wire and make splices and connections.
step 10,
once all the wiring is done and tested re-assemble your car.
step 11,
use the phillips tip to aim the headlights up and down.