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P51's HID Headlight (Projector) and Fog Conversion (PICS)

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
IMG_0042.jpg


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.
IMG_0045.jpg


Now its time to modify the housing to fit the protector
IMG_0050.jpg


Cut out all the plastic from the inside of the circle. I found that the barrel sander Dremel attachment worked the best.
IMG_0051.jpg


Now cut along the bottom to make room for the projector solenoid
IMG_0054.jpg


The Projectors (Note: They are upside down)
IMG_0048-1.jpg


Fit the projector into the housing
IMG_0056.jpg

IMG_0057-1.jpg

IMG_0058.jpg


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.
IMG_0059.jpg


Mark and Drill the holes to mount the Projectors
IMG_0062.jpg


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.
IMG_0089-1.jpg


Done (No shrouds at the moment)
IMG_0068.jpg


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.
IMG_0113.jpg


These are the LEDs not the HIDs
IMG_0116.jpg


Pax side Ballast locations
IMG_0084copy.jpg


Driver side Ballast locations
IMG_0085copy.jpg


HIDs vs Friends Subaruaruaru Stock Halogen
Lights-1.jpg


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.
0229081730a.jpg


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.
IMG_0088dcopy.jpg


Close up of Pax side Fog Ballast
IMG_0083.jpg


Done, Getting ready to go Skiing behind the Explorer :)
IMG_0075s.jpg

NOTE: The all Ford fleet.:thumbsup:

Wiringdaigram.jpg


Good Luck

EDIT: Daytime Pictures and Pics with shrouds installed on post 27
EDIT: Cutoff Pictures added on post 109
 



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Steeda04SVT

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Not trying to get this thread off topic, but how hard are they to change out from the factory ex mirrors to those with the puddle lights?
 



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MustangP51

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Not trying to get this thread off topic, but how hard are they to change out from the factory ex mirrors to those with the puddle lights?

Its not difficult to swap out the mirrors but its a nightmare having to fish wiring through the doors.
 






Jason c

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When I repaired my door wiring, I found that removing the door made things a lot easier. Might also do the same for adding wiring.
 






Steeda04SVT

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So just the inner door panel and everything then is accessible?
 






TowingExplorer

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Great write-up.

MustangP51, I see how you simply put holes in the back of the headlight housings and bolted the projectors in. In doing this, how did you rotate the projectors after in order to get the cutoff straight across?

I did not see any pictures of your cutoff against a wall or anything in the pages of this thread, do you have one?
 






MustangP51

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Great write-up.

MustangP51, I see how you simply put holes in the back of the headlight housings and bolted the projectors in. In doing this, how did you rotate the projectors after in order to get the cutoff straight across?

I did not see any pictures of your cutoff against a wall or anything in the pages of this thread, do you have one?

To be honest your best bet to level the projectors is to eyeball it. Make sure that when you drill your holes for the bolts make sure they are both the exact same distance from the headlight housing.

I never took a picture of the cutoff, but it is perfect. maybe ill take one tomorrow if i remember.
 






TowingExplorer

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To be honest your best bet to level the projectors is to eyeball it. Make sure that when you drill your holes for the bolts make sure they are both the exact same distance from the headlight housing.

I never took a picture of the cutoff, but it is perfect. maybe ill take one tomorrow if i remember.

Through all the reading I have read about HID aiming, I don't think anyone has ever said to "eyeball it" unless they were leaving access holes to get at some adjustment screws after.

Pictures would be great if you think they are worth showing. :salute:
 






MustangP51

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Through all the reading I have read about HID aiming, I don't think anyone has ever said to "eyeball it" unless they were leaving access holes to get at some adjustment screws after.

Pictures would be great if you think they are worth showing. :salute:

Believe me, get it as close to perfect as possible before closing them up. I left the lenses off the housings when I installed them for some final adjusting. After that the headlights can be adjusted with the factory adjusters.
 












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A4ayo

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How can i upgrade my 06 Mountaineer headlights to HID?
 






MustangP51

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How can i upgrade my 06 Mountaineer headlights to HID?

Depends on what you want to do. HIDs with projectors? or HIDs in the stock housings?
 






dgr6853

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Thought I would post these videos of my HID's

ontherd.mp4.html


ontherd2.mp4.html


lowbeamcloseandfaraway.mp4.html


highbeamcloseandfar.mp4.html
 






dgr6853

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Some additional pictures of my 2013 base Ex with HID kit. 35 watt kit at 5000K.

IMG_0994.jpg


IMG_0992.jpg


IMG_0989.jpg


IMG_0988.jpg


IMG_0986.jpg


IMG_0985.jpg


IMG_0982.jpg


IMG_0981.jpg


IMG_0980.jpg
 






MustangP51

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That looks sharp! Those halogen projectors have a pretty decent cutoff with the HIDs inside them.
 






dgr6853

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Thanks. I think the cutoff would be better with better bulbs. when I put the bulbs in originally The alignment was right. so, I had to open the hood and pull the drivers side out and then put it back in and play with it till it was right. So, Im thinking a better set of bulbs that have a better fit would give a more aligned spread and those are 5 or 6 thousand K. I would rather have the 4300k. so, I am going to try to order a set of the Mormoto 4300 bulbs and see where that lands me.
 












dgr6853

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They were (9005 L+) except that no one could tell me what the L+ stood for. so, I just went with 9005. I have been very pleased except that they shop where I got them didn't carry 4300 or 4500. Overall, I'm still happy with the setup because its a pretty good and even spread.
 



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I would definitely recommend getting the 4300k bulbs, I noticed an improvement in visibility when the road is wet. The darker pavement seemed to eat up the bluer light. Plus the 4300k will make it look like it came from the factory that way.
 






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