This is a tutorial to show people how I installed projector headlights into NG900/OG 9-3 headlight housings. To start, I will list the various tools and supplies that I used for this install. This is a long tutorial so grab a beer, or a soda for the under aged, and get ready rumble.
-Dremel tool with extension flex shaft
-many grinding stone dies(orange ones)
-cutting wheels
-cutting bit
-½” and ¼”sanding attachment with 80 and 120 grit
-Metal shears
-cordless drill
-screwdrivers
-wrenches
-spray bottle
-Sheet metal
-epoxy glue
-“FastSteel” metal epoxy
-high heat paint (clear, other colors)
-latex gloves
-duct tape
-lots of permanent markers
-ballasts
-AMP to bulb adapter
-H4 wiring harness
-D2S bulbs
Removal of the Reflector and Lens
First order of business is to remove the stock reflector from the housings. But before we do that we must first remove the bulb in the housings. IF you have not changed the bulbs before or was confused as to how the clip works, here are some pics to show you what the clip looks like.
Pull the H4 wiring harness off before removing the bulb. It is easier to pull the clip off of the bulb then vice versa. The clip removes by pushing the bent part at the top in then to the side. Once the H4 bulb is removed, remove the city light bulb. That is done by pushing the clips on the side inward then pulling it out.
The next step is to remove the stock lens. There will be atleast 6 clips around the lens to hold it on. I used a screw driver to pop off the clips. You may need to pry off the lens from the housing. Be careful not to rip or cut the gasket between the lens and the housing. Keep the gasket for use later when you put everything back together.
In order to take the reflector out you have to max out each adjustment. On some headlight housings this is fairly easy and others harder. This will depend on how the adjustment screws are anchored to the reflector. The ones that I had used for Rogo had the harder kind.
-Dremel tool with extension flex shaft
-many grinding stone dies(orange ones)
-cutting wheels
-cutting bit
-½” and ¼”sanding attachment with 80 and 120 grit
-Metal shears
-cordless drill
-screwdrivers
-wrenches
-spray bottle
-Sheet metal
-epoxy glue
-“FastSteel” metal epoxy
-high heat paint (clear, other colors)
-latex gloves
-duct tape
-lots of permanent markers
-ballasts
-AMP to bulb adapter
-H4 wiring harness
-D2S bulbs
Removal of the Reflector and Lens
First order of business is to remove the stock reflector from the housings. But before we do that we must first remove the bulb in the housings. IF you have not changed the bulbs before or was confused as to how the clip works, here are some pics to show you what the clip looks like.
Pull the H4 wiring harness off before removing the bulb. It is easier to pull the clip off of the bulb then vice versa. The clip removes by pushing the bent part at the top in then to the side. Once the H4 bulb is removed, remove the city light bulb. That is done by pushing the clips on the side inward then pulling it out.
The next step is to remove the stock lens. There will be atleast 6 clips around the lens to hold it on. I used a screw driver to pop off the clips. You may need to pry off the lens from the housing. Be careful not to rip or cut the gasket between the lens and the housing. Keep the gasket for use later when you put everything back together.
In order to take the reflector out you have to max out each adjustment. On some headlight housings this is fairly easy and others harder. This will depend on how the adjustment screws are anchored to the reflector. The ones that I had used for Rogo had the harder kind.