Here is my writeup for doing a Bi-Xenon HID Projector Retrofit for 96-01 Explorers, and HID Fog Light conversion for 99-01 Explorers.
Parts:
Clear Housings
E46 Bi-Xenon Projectors
3" Projector Shrouds
D2S HID Kit @ 5000k (Now 4300k)
H1 HID Kit @ 5000k (Now 4300k)
High Beam Controllers
3 Relays (30amp)
2 Diodes (3amp)
Fuse block (or inline)
To start you need to open up the headlight housings
First remove all the mounts from the housing
Then put the light on a baking tray with tinfoil in the oven and preheat the oven to 400 degrees. put the headlight in the oven and wait about 5-10 min, CONSTANTLY MONITOR IT and make sure it doesn't get soft.
Now its time to modify the housing to fit the protector
Cut out all the plastic from the inside of the circle. I found that the barrel sander Dremel attachment worked the best.
Now cut along the bottom to make room for the projector solenoid
The Projectors (Note: They are upside down)
Fit the projector into the housing
Now onto the High Beams, I didn't have the actual wires, so I desoldered the connection off the board and soldered on my own leads.
Mark and Drill the holes to mount the Projectors
I used some of my old LEGOS as spacers, and used Plexiglase to seal the light back up. (NOTE: Cut the excess screw off it will interfere with installation later.
Done (No shrouds at the moment)
Now This isnt necessary but its a nice touch. I put 3 LEDs in to come on when the mirror lights come on. When you click unlock on the key fob these come on and do give off quite a bit of light. Cover with silicone.
These are the LEDs not the HIDs
Pax side Ballast locations
Driver side Ballast locations
HIDs vs Friends Subaruaruaru Stock Halogen
Fogs
The only major modification needed to do the fog conversion is to modify the bulb socket. Cut out the center of the ring and thats all. Sorry about the piss poor pic but all I had was my cell phone camera.
Seal up the socket with some silicone and splice into the pigtail wire that goes from the chassis to the bulb, and connect that with the power in lead of the HID ballast.
Close up of Pax side Fog Ballast
Done, Getting ready to go Skiing behind the Explorer
NOTE: The all Ford fleet.
Good Luck
EDIT: Daytime Pictures and Pics with shrouds installed on post 27
EDIT: Cutoff Pictures added on post 109
Parts:
Clear Housings
E46 Bi-Xenon Projectors
3" Projector Shrouds
D2S HID Kit @ 5000k (Now 4300k)
H1 HID Kit @ 5000k (Now 4300k)
High Beam Controllers
3 Relays (30amp)
2 Diodes (3amp)
Fuse block (or inline)
To start you need to open up the headlight housings
First remove all the mounts from the housing
Then put the light on a baking tray with tinfoil in the oven and preheat the oven to 400 degrees. put the headlight in the oven and wait about 5-10 min, CONSTANTLY MONITOR IT and make sure it doesn't get soft.
Now its time to modify the housing to fit the protector
Cut out all the plastic from the inside of the circle. I found that the barrel sander Dremel attachment worked the best.
Now cut along the bottom to make room for the projector solenoid
The Projectors (Note: They are upside down)
Fit the projector into the housing
Now onto the High Beams, I didn't have the actual wires, so I desoldered the connection off the board and soldered on my own leads.
Mark and Drill the holes to mount the Projectors
I used some of my old LEGOS as spacers, and used Plexiglase to seal the light back up. (NOTE: Cut the excess screw off it will interfere with installation later.
Done (No shrouds at the moment)
Now This isnt necessary but its a nice touch. I put 3 LEDs in to come on when the mirror lights come on. When you click unlock on the key fob these come on and do give off quite a bit of light. Cover with silicone.
These are the LEDs not the HIDs
Pax side Ballast locations
Driver side Ballast locations
HIDs vs Friends Subaruaruaru Stock Halogen
Fogs
The only major modification needed to do the fog conversion is to modify the bulb socket. Cut out the center of the ring and thats all. Sorry about the piss poor pic but all I had was my cell phone camera.
Seal up the socket with some silicone and splice into the pigtail wire that goes from the chassis to the bulb, and connect that with the power in lead of the HID ballast.
Close up of Pax side Fog Ballast
Done, Getting ready to go Skiing behind the Explorer
NOTE: The all Ford fleet.
Good Luck
EDIT: Daytime Pictures and Pics with shrouds installed on post 27
EDIT: Cutoff Pictures added on post 109
