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Ford Truck Club Forum > GARAGE TALK > Garage Talk: Shop Class 101



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  #1  
Old August 25th, 2012, 01:18 PM
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Default 9007 Headlight Bulb Conversion for 1987-1991 Trucks

Hey guys, this write-up covers the conversion from the stock 9004 bulbs in the 1987-1991 Trucks to the 9007 bulbs used in the 92+ trucks. First off, many props to Booba5185 for helping me, I'm pretty dumb with electrical stuff but I called him and he talked me through it. This is fairly easy and if you know what exactly your looking for, you can get it done in 30min or less.

So to start, we'll need the bulbs, I bought the cheapest Oreillys had so I could get my lights changed as fast with as less as I could spend, they are $8.99 a piece here, EiKO brand:





Next, we need something with a point on the end, I tried little tiny screwdrivers and couldn't get them to work, my poor country butt can't afford a pick set so I improvised:



Here is our headlight plug:



First what we want to do is take the point of our whatever we're using, and prise the red piece out GENTLY:





Removed:



Now in this pic, I've already removed the wires, I did this so you could see the clips needed for the next part:



Inside the plug, above the wires are those ^ tiny clips, take your pointed tool, and GENTLY, lift them up and pull GENTLY on the wire out of the back, it took me a couple tries, but once all three are out you can pull all of the wires out with the rubber grommet.

In this pic, I've already switched the wiring from the 9004 spec to the 9007 spec, this is just to show you the rubber grommet and the wires:



This is the wiring diagram for the 9004's and 9007's, our(87-91's) are on the left, 92+ are right, we're switching to the right:



After you have the wires and rubber grommet out, pull them through the rubber grommet and switch them to the wiring on the right in the above pic, just push them back through the grommet.

Then push the wires back into the plug until you hear a snap, repeat til all three wires are in, then push the rubber grommet in place:



That pic you can see, green on the left, ground in the middle, red on the right, that's Highs, Ground, Lows.

Then put our little red plastic piece in:



Next we need to get the old bulbs out, twist the black collar looking thing on the headlight off, then pull the bulb straight out, your left looking at the hole in the housing where the bulb goes:



It's kinda hard to see in that pic, but the two bottom most tabs, either need filed off, clipped off, or cut off for the 9007 to go in. Once done the new light will push in place. Put the collar back on the bulb, plug your newly rewired plug in, and work on the driverside, it's exactly the same.

This is a before shot of mine with the bad passengerside 9004:


This is daytime after the 9007 conversion, I'll get a night pic tonight:


Happy bright lights!
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  #2  
Old August 25th, 2012, 01:50 PM
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Also, in order to safely do this swap, you MUST have done the 3g and headlight relays swap.
  #3  
Old August 25th, 2012, 09:29 PM
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Good job on the write up, the reason I say the 3G and headlight relays are a must is because the stock wiring harness and alternator are barely enough to keep up with the 9004s, my stock headlight had 10 volts at the plug, and killed my headlight switch in almost no time. The 9007s would create even more draw on the switch, causing it to burn up even faster. The 2G (stock) alternator is already prone to catching fire, so the additional draw from the 9007s would make that risk even higher.


89 F-150 5.0l AOD 2x4, 3.55 LS(+4), Converted to HO Roller, 3g Alt, GT40Ps, Y-pipe, Rerouted PCV, Dual Taurus E-fans, Explorer Injectors, Remote ICM, DIY Cold air, Rubber Vacuum System, Tranny cooler, Remote Tranny filter, Saginaw P\S swap, F350 Brakes, more.


  #4  
Old August 25th, 2012, 09:40 PM
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I was angled to the truck, that's why one if brighter than the tother, I did light up the neighbors across the street on lows! That pic by the way is with lows on.
  #5  
Old August 26th, 2012, 02:26 PM
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So what's the benefit?


1990 F150XLTLariat. 300I6. ZF. BDS. 36x16.5x15FC. SAS under construction.

How to: FTC Gallery.

How to: Brick steering column.
How to: Wiper motor removal.
Shop Class 101.
Door Tag Codes.
  #6  
Old August 26th, 2012, 03:39 PM
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Lights are way brighter and penetrate farther in the night.


89 F-150 5.0l AOD 2x4, 3.55 LS(+4), Converted to HO Roller, 3g Alt, GT40Ps, Y-pipe, Rerouted PCV, Dual Taurus E-fans, Explorer Injectors, Remote ICM, DIY Cold air, Rubber Vacuum System, Tranny cooler, Remote Tranny filter, Saginaw P\S swap, F350 Brakes, more.


  #7  
Old August 26th, 2012, 05:12 PM
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Yep, I was like Ray Charles for a bit after I took that pic...
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Old August 26th, 2012, 10:18 PM
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So next time I need bulbs I should do this.. My buddy should have a set of ultra 9007's sitting around from before he did hid's....


1990 F150XLTLariat. 300I6. ZF. BDS. 36x16.5x15FC. SAS under construction.

How to: FTC Gallery.

How to: Brick steering column.
How to: Wiper motor removal.
Shop Class 101.
Door Tag Codes.
  #9  
Old August 26th, 2012, 10:27 PM
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As long as you have headlight relays, which I'm pretty sure you do, you'll be descent. If you had a 3G you'd be set for sure.


89 F-150 5.0l AOD 2x4, 3.55 LS(+4), Converted to HO Roller, 3g Alt, GT40Ps, Y-pipe, Rerouted PCV, Dual Taurus E-fans, Explorer Injectors, Remote ICM, DIY Cold air, Rubber Vacuum System, Tranny cooler, Remote Tranny filter, Saginaw P\S swap, F350 Brakes, more.


  #10  
Old August 26th, 2012, 10:38 PM
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I have the relays, but not 3g. I'm not gonna bother with it right now. With the 9004 ultras and high/low mod it's good enough for now


1990 F150XLTLariat. 300I6. ZF. BDS. 36x16.5x15FC. SAS under construction.

How to: FTC Gallery.

How to: Brick steering column.
How to: Wiper motor removal.
Shop Class 101.
Door Tag Codes.


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