Mr911
Member
Hello everyone! I am posting this "How-To" for those of you with 2002-2005 Ford Explorers (and possibly other makes/models) that are looking to replace your current OEM fog/driving lights with LED Warning/Driving lights. For this project I chose the Whelen PAR 28 as an "exact-size" fit. Below will be steps with corresponding pictures:
1) I found it easier to drive the truck up on ramps for easier access. Once on the ramps you will need a 1/4"ratchet with a short extension and a 7mm socket to remove the OEM assembly. Unplug the wire from the driving light bulb and tuck back to access the 3-7mm screws holding the assembly in place. (There are 2 on top at the 11 and 1 o-clock position and 1 on the bottom at the 6 o-clock position) Remove all three and take the housing out of the mounting location. Do this for both the left and right assembly.
2) Disassemble the assemblies by removing the rear reflectors from the black mounting rings. NOTE: the glass lenses are glued in from the front and will come off by carefully cutting gasket with a utility knife and prying the lens off with two flat-tipped screwdrivers. Once the glass lens is removed you can scribe out the remaining residual glue with a flat screwdriver.
3) Using a Dremel tool with a cut-off wheel, cut the rear of the mounting ring (where the retaining clips hold the reflector in). Once cut off sand the remaining edge off until smooth.
4) Using .040 thick aluminum (or other similar material), make flat mounting plates, cut and trimmed to fit, to be attached to the plastic mounting rings.
5) Using 1/8" pop-rivets, attach the backing plates to the rings
6) Mark the center and drill a hole in the aluminum for the wires and boot to fit through. Measure, mark and drill the backing plates to correspond with the 4 mounting studs on the rear of the PAR 28's.
7) Using 4-#8 (1/2") sheet metal screws with hex heads CAREFULLY screw them into the studs protruding from the rear of the PAR 28 light head.
8) OPTIONAL: After dry-fitting everything, disassemble and paint your "NEW" mounting assembly satin black, let dry thoroughly and re-assemble.
9) Re-attach the new LED warning/driving light assembly to the vehicle, connect the wires to their proper locations and enjoy:celebrate:!
1) I found it easier to drive the truck up on ramps for easier access. Once on the ramps you will need a 1/4"ratchet with a short extension and a 7mm socket to remove the OEM assembly. Unplug the wire from the driving light bulb and tuck back to access the 3-7mm screws holding the assembly in place. (There are 2 on top at the 11 and 1 o-clock position and 1 on the bottom at the 6 o-clock position) Remove all three and take the housing out of the mounting location. Do this for both the left and right assembly.
2) Disassemble the assemblies by removing the rear reflectors from the black mounting rings. NOTE: the glass lenses are glued in from the front and will come off by carefully cutting gasket with a utility knife and prying the lens off with two flat-tipped screwdrivers. Once the glass lens is removed you can scribe out the remaining residual glue with a flat screwdriver.
3) Using a Dremel tool with a cut-off wheel, cut the rear of the mounting ring (where the retaining clips hold the reflector in). Once cut off sand the remaining edge off until smooth.
4) Using .040 thick aluminum (or other similar material), make flat mounting plates, cut and trimmed to fit, to be attached to the plastic mounting rings.
5) Using 1/8" pop-rivets, attach the backing plates to the rings
6) Mark the center and drill a hole in the aluminum for the wires and boot to fit through. Measure, mark and drill the backing plates to correspond with the 4 mounting studs on the rear of the PAR 28's.
7) Using 4-#8 (1/2") sheet metal screws with hex heads CAREFULLY screw them into the studs protruding from the rear of the PAR 28 light head.
8) OPTIONAL: After dry-fitting everything, disassemble and paint your "NEW" mounting assembly satin black, let dry thoroughly and re-assemble.
9) Re-attach the new LED warning/driving light assembly to the vehicle, connect the wires to their proper locations and enjoy:celebrate:!