How-To Convert Sealed Beam to Composite Headlights S-series
 

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)

(source s10 forum)