05-07 CONVERSION instructions. ( here ) - Ford Powerstroke Diesel Forum
99-03 7.3L Exterior Discussion Body and Accessories Talk

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  #1  
Old 02-28-2010, 04:36 PM
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Exclamation 05-07 CONVERSION instructions. ( here )

OK, man, for how many people did this why did anyone NOT make a write up??

Ill take a hit for the team. and write away!

THIS is for 99.5-04 SD 05-07 conversion!

Now youll need..

**NOTE**IF you need more parts..or need the parts period.. try..
-Ebay!!

-certifit.com http://www.certifit.com/catalogs/Catalog2.pdf

-Or any sponsor we have that might stock these items.


Parts

- 05-07 front bumper -approx 1-200$ depending...plus paint..additional 150$
- 05-07 Lower valence - hopefully comes with bumper
- 05-07 Upper valance- hopefully comes with bumper
- 05-07 Fog lights ( optional ) - 26$ each brand new, need to buy bolts and nuts..3.00$
- 05-07 Head lamps -1-300$ depending where you get them.
- 05-07 Grille - 1-200$ depending on the grille
- 05-07 Header panel ( optional ) - no idea..gotta price one out
- 05-07 9008/H13 pig tails fir head lamps - 6.99$ each off ebay!


Supplied by another member ( part numbers off cerfit.com )

The list with part numbers:
* Bumper front chrome -- FDF320CA
* Bumper moulding front, paint to match -- FDF328BB
* Air deflector, valance panel lower -- FDF 345BA
* Fog light assembly R -- FDF382B3
* Fog light assembly L -- FDF382B4
* Bumper mounting bracket R -- FDF327C1
* Bumper mounting bracket L -- FDF327C2



**NOTE**
The original FOGS will not work unless new brackets are made, they are totally mounted differently!


Youll also need to..

PAINT THE UPPER VALENCE!..it just looks better!

Ok lets begin with this..

YOU DO NOT NEED THE HEADER PANEL!...it just makes life way easier and makes the install better..just buy it!

Start..

Open hood..

Remove 4 upper philips screws on grille shell, grab the sides and wiggle it back and forth. IT WILL come out!

Remove headlamp!

1 Pull up and remove the two upper headlamp clips.
2 Release the lower headlamp clip.
3 Position the headlamp so the electrical connector can be accessed.
4 Disconnect the headlamp electrical connector.

If you look at the top of the light youll notice 2 metal tabs with an "L" shape bend, lift up on them..there a *****..maybe try some WD40 or something..once removed youll see how the light pulls forward, disconnect the main light plug.

**NOTE**

IF!!! you are having problems getting the headlight lower clip out or the inner metal clip and the lower one, screw the adjusters 100% clockwise till they thread right out, the headlight screw adjuster will stay in the head panel and you can take them out after!!

Now remove the Parking lamp assembly , 2 Philips screws i believe, and itll come right out, disconnect the plugs and lay off to the side!

Remove bumper.

1 UNDO bolt on side of bumper support, one on pass side and one on drivers side, both are in the fender well.
2 Disconnect the fog lights if you have them
3 Take the block heater cord out
4 Move the lower rubber cover off the clips
5 Grab a buddy
6 unbolt the 4-18mm bolts on the front bumper horn, the bumper will fall off if your not holding it!
7 place bumper off to the side!

Remove header panel

Youll find 2 8mm screws behind headlight on each side and 2 hidden on each side by the rad support, you cant miss them, undo all 4 and itll come right out, there is a couple "christmas tree clips" hidden behind the header panel that need to be undone, also undo the ones on the upper side of the header panel!! this will come out with persuasion.

**NOTE**

If you are having issues getting it around the AC condenser, remove the 2 8mm bolts on the upper support brackets, remove the brackets and you can move it a bit side to side, this helped with me!

( drink a beer )

Ok now that your truck looks alike a buffalo wrote it off and its only good for parts, start tossing stuff on..


** IF YOU ARE CUTTING HEADER PANEL PLEASE FOLLOW THESE TEMPLATES **


A very, VERY SPECIAL thanks to BamaSixGun for the pictures and drawings!!






Install new header panel..thats self explanatory!

** NOTE **


OR YOULL NEED to trim it out, there are pictures on here ..ABOVE ^^^..also if you do not change this the grille will not clip in on the bottom, my 07 did not, youll need to secure it with 2 big zip ties, you cannot see them, and the grille does not move!

Start with front bumper, if your bumper did not come with factory fogs you can buy them from TYC for 26$ each, comes with brackets and everything, NO HOLES have to be drilled just cut the plastic locating tabs off the new fog light bracket on the top as the upper bumper valance will hit them!

Place bumper up to truck, YOU CANNOT RE-USE the side brackets, they will not work, this is okay as the bumper will not fall! or wiggle! Put the 4-18mm bolts back in and put the back nuts on them, tighten slowly, make it snug enough you can move the bumper up/down and side to side, DO NOT TIGHTEN YET!!

Install new Headlamps.Youll need to splice in the new connector first. Cut off the old headlight connector, splice in the new one, before doing so use a test light and check for low beam and highbeam . To use test light just turn lights on to low beam and touch the metal tabs on the connector with the probe when it lights up mark that wire as low, turn highs on and do the same, mark that wire high, now the other is ground. the new connector will come pre labeled and youll just need to use Heat shrink butt connectors or solder and heat shrink. finish install head lamps, the signal and marker lights do not need to be spliced as they are the same! you can tighten these right into place!

**NOTE**

For those wondering- Pin #1 is low beam, #2-ground, #3 high beam on the 9008 bulb.

You do not need the upgraded harness unless running higher wattage bulbs from what i hear. so if you upgrade just got HID !



Now install your new grille. pop the bottom back into place and put the 4 screws back in the top of the grille!, easy!

( Drink a beer )


Now youll need your buddy to help you adjust your bumper side to side and up and down, you may have a bit of overhang on the drivers front side and as ive seen this is normal, you can hardly tell so dont worry its normal, this will take awhile to get it in the place you need it!

now once this is all done tighten everything up and shut your hood, check to make sure all works well and BANGO! you have an 05-07 front end!

remember to plug everything back in!

Enjoy!!


***NOTE***you dont have to switch the headlights if you dont want too..heres a pic of my truck before!


***NOTE*** THIS IS what it will look just to give you an idea.mm i love her


Last edited by 03_Turbo7.3; 01-30-2011 at 07:51 AM.
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Old 02-28-2010, 05:41 PM
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Looks pretty sweet!If you don't mind me asking,how much for all the parts-minus paint costs? Did you buy new oe,aftermarket?
Now for the fog lights-mine's a 99,it does have the pull out on the light switch for fogs like the wife explorer does,what's needed to add them and will the switch work like factory-or always on with headlights?
Thanks
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Old 02-28-2010, 05:47 PM
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looks good man.
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Old 02-28-2010, 06:05 PM
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Price list would be cool. Looks good!
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Old 02-28-2010, 06:59 PM
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Hopefully someone stickys this write up too.. PRICE LIST IT UP....

my cost 338$ on used parts..

100$ bumper..with paint add 148$
100$ grille... needed new emblem 38$
100$ front head lights
56$ for fog lights!

Last edited by 03_Turbo7.3; 02-28-2010 at 07:03 PM.
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Old 03-01-2010, 02:05 PM
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impressed...certifit is fairly reasonable on their prices. i hadnt decided if i want a chrome one or the one ya paint. good write up though.
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Old 03-01-2010, 04:51 PM
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Great info-thanks man! Be looking into after taxes come back!
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Old 03-02-2010, 02:51 PM
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Old 03-02-2010, 04:00 PM
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Nice info! I've got most of my parts sitting in my garage.....waiting on my HID's. (Header panel, grille, grille emblem & Headlamps) I'm keeping my orig bumper & will be trimming the grille.

If I go w/ a 05+ bumper later, I've only got $60 in this new grille (+$24.41 for emblem) and could easily buy another one.
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Old 03-02-2010, 04:04 PM
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Quote:
Originally Posted by Budha View Post
Nice info! I've got most of my parts sitting in my garage.....waiting on my HID's. (Header panel, grille, grille emblem & Headlamps) I'm keeping my orig bumper & will be trimming the grille.

If I go w/ a 05+ bumper later, I've only got $60 in this new grille (+$24.41 for emblem) and could easily buy another one.

Nice.. post some pics up!
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