How-To Convert Sealed Beam to Composite Headlights - S-10 Forum
 
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post #1 of 6 Old 09-12-2011, 09:45 PM Thread Starter
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How-To Convert Sealed Beam to Composite Headlights

Not sure how many people will do this but I decided to do this today. The last How-To did not have any pictures

What you need

Parts:
Composite Grille
Left and Right Composite Headlights with brackets (only need high and low beam harness, Turn signal lights and plugs are same for both vehicles)
Good portion (9" or so) of Headlight pigtails.

Tools:
1/4 Socket Wrench
6" Extension
7mm Socket
10mm Socket
Soldering iron
Solder
Shrink Wrap or Electrical tape.

Start off by removing the Sealed Beam Grille
6 bolts, 4 up top and 2 in the center (in red circles)
there are also 4 clips holding the bottom of the grille to the Core support. Be careful these easily break.




Next, remove the Sealed beam headlights by removing the 4 bolts holding them in. (Circled)



Remove Sealed Beam Headlight plug from wiring harness.

Drivers Side: headlight plug has 5 wires (2 tan, 2 Green 1 Blue). Pigtail from Headlight has 4 wires (1 Tan, 1 Green, 1 Black, 1 Blue)

For both the Green and Tan wires, solder the 2 wires from the Truck harness to same color wire from the headlight pigtails. Green-Green, Tan-Tan.

Solder Blue wire to Blue wire.

Shrink Wrap or tape over open wire. Prefer shrink wrap to keep water out.

Connect Black wire from headlight harness to a ground.



Passenger Side: Headlight plug has 3 wires (1 Green, 1 Tan, 1 Black)
The Headlight Pigtail has 4 wires (1 Green, 1 Tan, 2 Black)

Connect, Solder and shrink wrap each wire to same color wire on harness.

Installing headlights: 4 bolts hold in the Headlight buckets, but I am only using 3. 1 of the bolts gets put in from behind the core Support. I did not feel like removing the airbox and battery to intall these bolts.

The lower bolt on the outside is the one that gets put in from behind the core support. Also, Sealed beam trucks do not come with the clips for the 2 inboard bolts.(if someone knows the name of these clips please let me know, I am having a brainfart). Do not forget these clips.







Greg
2013 Focus ST(3), Tuxedo Black, Cobb Accessport Tuner, Steeda Shifter/Bracket, 20% Tint
1996 S10 LS Ext Cab, 4.3, Auto - 3"/3.5"
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post #2 of 6 Old 09-12-2011, 09:50 PM Thread Starter
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Re: How-To Convert Sealed Beam to Composite Headlights

Dont forget to test lights to make sure they all work.


Install Grill. I painted mine body color. I was a quick job its a (20 footer job, only looks good from 20 feet away)

Greg
2013 Focus ST(3), Tuxedo Black, Cobb Accessport Tuner, Steeda Shifter/Bracket, 20% Tint
1996 S10 LS Ext Cab, 4.3, Auto - 3"/3.5"
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post #3 of 6 Old 09-12-2011, 11:54 PM Thread Starter
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Re: How-To Convert Sealed Beam to Composite Headlights

Not sure how many people will do this but I decided to do this today. The last How-To did not have any pictures

What you need

Parts:
Composite Grille
Left and Right Composite Headlights with brackets
Good portion (9" or so to work with) of Headlight pigtails. (only need high and low beam harness, Turn signal lights and plugs are same for both vehicles)

Tools:
1/4 Socket Wrench
6" Extension
7mm Socket
10mm Socket
Soldering iron
Solder
Shrink Wrap or Electrical tape.

Start off by removing the Sealed Beam Grille
6 bolts, 4 up top and 2 in the center (in red circles)
there are also 4 clips holding the bottom of the grille to the Core support. Be careful these easily break.




Next, remove the Sealed beam headlights by removing the 4 bolts holding them in. (Circled)



Remove Sealed Beam Headlight plug from wiring harness.

Drivers Side: headlight plug has 5 wires (2 tan, 2 Green 1 Blue). Pigtail from Headlight has 4 wires (1 Tan, 1 Green, 1 Black, 1 Blue)

For both the Green and Tan wires, solder the 2 wires from the Truck harness to same color wire from the headlight pigtails. Green-Green, Tan-Tan.

Solder Blue wire to Blue wire.

Shrink Wrap or tape over open wire. Prefer shrink wrap to keep water out.

Connect Black wire from headlight harness to a ground.



Passenger Side: Headlight plug has 3 wires (1 Green, 1 Tan, 1 Black)
The Headlight Pigtail has 4 wires (1 Green, 1 Tan, 2 Black)

Connect, Solder and shrink wrap each wire to same color wire on harness.

Installing headlights: 4 bolts hold in the Headlight buckets, but I am only using 3. 1 of the bolts gets put in from behind the core Support. I did not feel like removing the airbox and battery to intall these bolts.

The lower bolt on the outside is the one that gets put in from behind the core support. Also, Sealed beam trucks do not come with the clips for the 2 inboard bolts.(if someone knows the name of these clips please let me know, I am having a brainfart). Do not forget these clips.






Dont forget to test lights to make sure they all work.


Install Grill. I painted mine body color. I was a quick job its a (20 footer job, only looks good from 20 feet away)

Greg
2013 Focus ST(3), Tuxedo Black, Cobb Accessport Tuner, Steeda Shifter/Bracket, 20% Tint
1996 S10 LS Ext Cab, 4.3, Auto - 3"/3.5"
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post #4 of 6 Old 09-28-2011, 10:12 AM Thread Starter
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Re: How-To Convert Sealed Beam to Composite Headlights

Not sure how many people will do this but I decided to do this today. The last How-To did not have any pictures

What you need

Parts:
Composite Grille
Left and Right Composite Headlights with brackets
Good portion (9" or so to work with) of Headlight pigtails.
You only need high and low beam harness as the Turn signal/Running lights plugs are same for both vehicles.

Tools:
1/4 Socket Wrench
6" Extension
7mm Socket (for Grille)
10mm Socket (Headlight bracket bolts)
Soldering iron
Solder
Shrink Wrap or Electrical tape.

Start off by removing the Sealed Beam Grille
6 bolts, 4 up top and 2 in the center (in red circles)
there are also 4 clips holding the bottom of the grille to the Core support. Be careful these easily break.




Next, remove the Sealed beam headlights by removing the 4 bolts holding them in. (Circled)



Remove Sealed Beam Headlight plug from wiring harness.

Drivers Side: headlight plug has 5 wires (2 tan, 2 Green 1 Blue). Pigtail from Headlight has 4 wires (1 Tan, 1 Green, 1 Black, 1 Blue)
For both the Green and Tan wires, solder the 2 wires from the Truck harness to same color wire from the headlight pigtails. Green-Green, Tan-Tan.
Solder Blue wire to Blue wire.
Shrink Wrap or tape over open wire. Prefer shrink wrap to keep water out.
Connect Black wire from headlight harness to a ground.




Passenger Side: Headlight plug has 3 wires (1 Green, 1 Tan, 1 Black)
The Headlight Pigtail has 4 wires (1 Green, 1 Tan, 2 Black)

Connect, Solder and shrink wrap each wire to same color wire on harness.



Installing headlights: 4 bolts hold in the Headlight buckets, but I am only using 3. 1 of the bolts gets put in from behind the core Support. I did not feel like removing the airbox and battery to intall these bolts.

The lower bolt on the outside is the one that gets put in from behind the core support. Also, Sealed beam trucks do not come with the clips for the 2 inboard bolts.(if someone knows the name of these clips please let me know, I am having a brainfart). Do not forget these clips.






Dont forget to test lights to make sure they all work.


Install Grill. I painted mine body color. I was a quick job its a (20 footer job, only looks good from 20 feet away)

Greg
2013 Focus ST(3), Tuxedo Black, Cobb Accessport Tuner, Steeda Shifter/Bracket, 20% Tint
1996 S10 LS Ext Cab, 4.3, Auto - 3"/3.5"

Last edited by beandip; 02-18-2012 at 02:18 AM.
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post #5 of 6 Old 10-02-2011, 06:27 PM
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Re: How-To Convert Sealed Beam to Composite Headlights

just let me know when you are done

-Jonathan



2000 Sonoma Extended cab 2.2L 5 Speed with Hurst short throw shifter, 3/4 Drop on staggered gray boss 338 18s, Flowmaster original 40 series.
My Project thread--->https://www.s10forum.com/forum/f30/pr...driver-361848/

{PROJECT ZR2} 2000 S10 ZR2 200,XXX miles, 31x10.5 BFG KM2 MT on 15" Pro Comp 152s, Iron front diff, 1.5" T-bar crank & custom bumpers & shackles, + more
https://www.s10forum.com/forum/f30/be...ct-zr2-485836/

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https://www.s10forum.com/forum/f30/da...status-520683/

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post #6 of 6 Old 10-04-2011, 10:37 AM Thread Starter
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Re: How-To Convert Sealed Beam to Composite Headlights

That should be it.

Greg
2013 Focus ST(3), Tuxedo Black, Cobb Accessport Tuner, Steeda Shifter/Bracket, 20% Tint
1996 S10 LS Ext Cab, 4.3, Auto - 3"/3.5"
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