Proper headlight installation

[lanky 44]

I am getting ready to install relays for my front headlights, and I'm replacing the outer two lamps right now because they both went bad. I have been fighting with the stupid spring system that fastens the bulb assembly.

Is the spring for the inner trim, the bucket, or both? Since the inner trim has the tab with the hole I figure it's at least for that.

Does the front end of the spring curve upward or downwards? Mine was facing downward when I took the old lamps out.

What is the darn secret with these things? I can't believe how difficult it is to assemble everything and I'm scared to death I will break the original inner trim or the new lamps. To be clear the old bulbs fight just as much, and from comparison I'm sure the bulbs aren't the issue.

Why was such a thick spring used? Even with pliers and no bulb/bucket in the way I can barely stretch the spring at all. Seems like a softer one would work just as well right? 

[Shep69 149]

I only put my lights in a few weeks ago and yes  I must agree that the springs are tight. I put the spring in place first facing down and then attach the inner ring , carefully draging it over the light before doing up the two screws. The rings are razor sharp so be careful. 

 

[Caseyrhe 650]

Do a search on You tube, couple good videos

[Shep69 149]

 

[bigmal 225]

This is very helpful. I started changing my outside lights for H4 and broke a chrome ring. It always amazes me when people know exactly where to find these videos.

[Raven R code 281]

Good info.....heading down this road right now. The headlights have been fighting me for at least 2weeks now!

[JET 445 43]

Don't be surprised if the trim rings break, they oxidise on the spot welds and just fall apart when you put pressure on them. New ones are cheap and easy to get.

[lanky 44]

My car is not disassembled so the above video isn't much help. I looked around but am still unsure if it's better to fasten the 2 screws first and use some kind of hook tool to stretch the spring OR to try hooking the spring first and then do the screws. It looks like the spring has to attach to the trim ring and bucket. There's so little room to work, I could use a 3rd arm. 

[69 Cruzin 4]

I just recently replaced all 4 of my headlights. Put the 2 screws in the trim rings and get them started but don't tighten.  I purchased a t-hook used to replace brakes from my local Advance Auto. Make sure spring is hooked in the back of the adjuster bucket and in a position where you can easily hook with tool. 

It will take some force to pull and latch in bucket and trim ring ...so wear some sort of eye protection. 

Once spring is I place, then tighten s rews.

[lanky 44]

OK thanks I will try that.

[bigmal 225]

22 hours ago, Caseyrhe said:

Do a search on You tube, couple good videos

Hi mate, You have been liked by a guy 'samzyantew' I suspect you will be hit up to by non prescription viagra as well.

[ralt962 11]

I just finished putting all my headlamps in.  I noticed a couple of things.  The new cans sit taller than the originals.  This makes stretching the spring that much more difficult.  I used the old cans on all but one lamp.  I noticed that the new springs have the hook go the opposite direction.  So I used an old spring with the new bucket.  Still very difficult.  This was with a new aftermarket fender extension.

So last ditch I shaved a little bit of material off of the three points in the fender extension where the can rides.  This allowed it to sit in a lttle farther.  That worked and I was able to get the headlamp in.

Use the original cans if you can, watch the spring direction and last ditch shave some off of the 3 little nubs.  I wouldnt take much off. But it helped me.

[lanky 44]

Ok you guys... I have done many different projects when it comes to vehicles. Not my first try, try again, try again scenario. I am so bleeping frustrated trying to get the dang lamps and inner trim on. I borrowed a hook tool from a friend, and on my second attempt the thing broke. After the last however long ago I decided I wouldn't try again for awhile to let my anger subside.

I have to ask this question again, is it necessary to have such a strong spring? Before the hook tool broke I was still not reaching the hole in the trim. I am not only worried about repairing a second trim ring, but also worried I'll snap the headlight bucket where the spring rides. Steaming right now! I tried both ways (starting the 2 screws and not starting the screws). I am almost at the point where I'm spring shopping....

[RPM 1,190]

My springs, like most I'm sure, are very stiff. Valve spring stiff. I already had a T handle hook tool which I used. It is imperative they the spring is set up properly before hooking the other end. 

I followed this video with success. 

https://youtu.be/hYJ5t3gis6U

[JET 445 43]

I just replaced a headlight today, it is easier to put the spring on the trim ring first and then put the screws in. You don't need a tool to stretch the spring, just tilt the trim ring in towards the spring, hook it on, then insert your headlight, push the trim ring into position and install the screws.

[det0326 179]

Yep  I did as Jet did, was really easy.  So many people having trouble tho leads me to believe that something must be different on some tho. I know that some of the distributors were selling replacement springs that were made wrong. The hooks were oriented 180 degrees wrong I believe . They will hook on being 180 off but may be more difficult. Don't know if this may be some people's problem or not. 

[bigmal 225]

I had difficulty with mine as well. I ended up using a piece of wire in a loop about 3" long with one end wrapped around a 3" nail as a handle. I hooked the spring through the ring first and used the wire to pull the spring which allowed me to get the ring around the lamp and then put in the screws. A third hand would have helped. It took a couple of goes to get the technique right but it worked for me.

[Brian Conway 264]

It's been a while...  I took this picture because I wanted a reminder of how I got this basic maintenance  done on my car.  I remember it was a bit of a three handed PITA.  Th picture shows what I had hooked up or installed.  Next step was to plug in the headlight bulb behind the trim ring .  Then holding the plugged in bulb with the trim ring on the outer perimeter move everything toward the rear of the bucket.  I think it need to rotate till snug ?  Next install the , trim ring and bulb , to the bucket and attach with the retaining screws.  That's how I remember it anyway.  Looking at this picture I can see stamped into the back of the bucket ' R L '.  Obviouly the Left side of the car so what's that all about ?  Brian

[lanky 44]

I broke a second (brand new) hook tool right now trying to do this. Someone please tell me why they chose to use such a strong spring. I will buy one more tool and if that doesn't work I'm finding different springs. I'm pretty sure a softer spring would be fine...

When everything is in place, and I pull the spring, both the end of the tool and the spring end hit the back edge of the tab on the trim ring. This moves it forward making attachment impossible. 

Compared to other cars I've worked on classic mustangs have always been near the top for ease of access/ designed to be maintained or worked on. Why they designed the lamps this way I don't know...I'm already dreading future bulb replacement... I'm shocked to read some of you haven't had problems with this before!

[RPM 1,190]

My guess at why it's so difficult is because you're attempting it from the front, not the rear. 

Not sure what tool you're using which breaks, but I've used this tool for many uses without fail. 

[Ridge Runner 1,112]

Adjust your adjusters in ,they are probably out to far to stretch the spring . With them threaded In the distance needed to hook the spring is less .the springs are strong to keep the bulb from rattling ,once you hook the spring readjust the bulbs 

[Ridge Runner 1,112]

The springs go in first ,they should clip into the buckets and stay.The cans go next hooked to the adjuster ,adjusters screwed in . Set the bulb in place with the thim ring on ,screw the to screws into the trim ring ,hook the spring with your tool and attach the spring to the stainless retainer tab ,dont let the bulb slip out of the notches ,when the spring is hooked readjust the headlights

[JET 445 43]

10 hours ago, lanky said:

I broke a second (brand new) hook tool right now trying to do this. Someone please tell me why they chose to use such a strong spring. I will buy one more tool and if that doesn't work I'm finding different springs. I'm pretty sure a softer spring would be fine...

When everything is in place, and I pull the spring, both the end of the tool and the spring end hit the back edge of the tab on the trim ring. This moves it forward making attachment impossible. 

Compared to other cars I've worked on classic mustangs have always been near the top for ease of access/ designed to be maintained or worked on. Why they designed the lamps this way I don't know...I'm already dreading future bulb replacement... I'm shocked to read some of you haven't had problems with this before!

Like I said before, put the spring on first before you install the headlight, then pull it into position and install the screws- easy.

[ralt962 11]

On 12/17/2017 at 11:42 AM, det0326 said:

Yep  I did as Jet did, was really easy.  So many people having trouble tho leads me to believe that something must be different on some tho. I know that some of the distributors were selling replacement springs that were made wrong. The hooks were oriented 180 degrees wrong I believe . They will hook on being 180 off but may be more difficult. Don't know if this may be some people's problem or not. 

I found I had backwards springs.  I still had my originals that were rusted.  But the new ones were 180 deg off.  

Lanky, are you using new fender extensions?  I had one new one original.  The original was easier.  I did hook the spring in first then pushed the headlamp in to start the adjusting screws.  Not easy and it is try try again.  

But on the new fender extension I struggled until I shaved a bit off the 3 nubs that position the headlamp can.  With this tight of spring I dont worry about it being loose.  But it made the difference about getting those on.  I also used and original spring for that can.  I took down the nubs a little at a time until it worked.

[ralt962 11]

One last thing.  Make sure the locators on the headlamp are lined up with the indents in the can.  Sounds basic, but they continued to pop out and slide around.  If they aren't lined up, nothing will work.