Headlight Removal

[9091SHOs]

Hey guys,
I am looking to replace the headlights and corners on my '91 with some fresher units that I've had for a while. Outside of the 2 locking tabs on the top of the headlight housings that secures them to the header panel and the one nut on each of the corner lights, what else is there?

Thanks!

 

[sperold]

You have to pull the tabs on those retainers and get in behind the rubber part with a box end wrench to close the rubber fingers in so that the whole assembly will slide out. If you break a metal tab, they are available from any parts store as Ford put them on everything for quite a few years.

**** your adjusters while they are out and accessible, especially the bottom one.

 

[Jbeck]

^^^ exactly what he said

 

[9091SHOs]

Thanks guys!

 

[Irish Pride]

The is a 3rd retaining clip down low. No need to push on anything with a box end wrench. Gen1 headlights pop right out once you remove the clips.

Use a 90° pick to pry out on the clips from one side to the other side. They will pop out in no time.

I always make sure that my lights are properly aligned where I want them and then I break the ears off of the lower clips. Makes removing them so much easier the next time.

 

[Irish Pride]

Use the pick to pry out in these spots. Dont bother trying to use snap ring pliars. The pick makes it so much easier.

 

[9091SHOs]

So how do you get at the lower clip?

 

[Irish Pride]

From inside. It's accessible without having to remove anything.

 

[9091SHOs]

I am staring behind the headlight and I see no way to get at that lower clip. I've got to be missing something. I have the newer headlight and see where the lower clip would go but I can see or find it on the light that is currently in the car.

 

[zoomlater]

On Gen 2 cars, the same clip is there. Try getting a mirror to see where it is and use a pick to catch the hole so you can pull it up

 

[9091SHOs]

Thanks guys. I found the lower clip on both sides...now just trying to get it to come out!

Thanks again for all of your help

 

[BaySHO Performance]

Yes, remove the two clips for the horizontal adjustment. Don't see how to get at the clip on the vertical adjustment as it's buried. So I separate the two halves of the vertical mechanism by using a 4mm socket turned clockwise (not anticlockwise). When you pull the old headlight, note that the rod that sticks straight back at the bottom has a flat in it. Make sure that the rod on the new headlight has the same orientation.

You will probably find that you won't be able to get the 4mm socket on to one of the horizontal adjusters. Cut a V in the housing with a dremel tool / cutting wheel.

When installing the new corner lights (11mm), make sure that you don't over tighten them: you run the risk of the lens popping off.

 

[FastCAD]

Hey guys,
I am looking to replace the headlights and corners on my '91 with some fresher units that I've had for a while. Outside of the 2 locking tabs on the top of the headlight housings that secures them to the header panel and the one nut on each of the corner lights, what else is there?

Thanks!

drilling a weep hole at the bottom rear of the assembly helps with condensation that builds up inside.

 

[NoSlo]

The bottom clip can be gotten off. The clips won't slide up and off because they catch on a tab above the clip, besides that they need to be spread to get the side clips out of the grooves on the pin.

You can bend the side tabs completely out so they don't catch in the pin groove.

You have to pull the top away while simultaneously lifting up. Grab the top part of the clip that sticks out with angled pliers, and give it rocking twists until it gets by the retention tab.

Alternately wedge a thin shim into the top between the back of the clip and the body, to lift the clip away from the tab. Then a wide screwdriver from the back to work it up and off.