Headlight questions...again

[jaguar72]

All,

I know this topic has been addressed (a lot) before but perhaps someone can help me on this: I recently decided to bite the bullet replace the original headlights (the dreaded cracked mounting boss...) on my 2002 and ordered (online) OEM parts 3W6Z-13008-AD (left/driver side) and 3W6Z-1008-AC (right/passenger side) and was told these were not the correct part numbers for a 2002 (1W6Z-13008-AC and 1W6Z-13008-AD were given as the correct numbers).

I knew the numbers I had used were for a 2003-2005, but I can't see as how there is any difference. I know my lights have a bolt and washer while the newer lights use a threaded stud embedded in a strengthened (ribbed) boss and a nut, but I thought everything else was the same. The lights listed for the 2002 are significantly more expensive, by the way (and the other ones are by no means cheap...).

Anyhow, does anyone have any insight for/experience with this, i.e., do you think the 3W6Zs (2003-2005) will fit a 2002? I am inclined to think they will. I thought as far as OEM headlight fit was concerned they were all the same.

I would be eternally grateful for any advice.

By the way, I earlier tried some aftermarket lights but was not happy with the fit.

V/R,
Gary Jenkins/jaguar72

[DavidA]

Re: Headlight questions...again

The lights are the same. They WILL fit.

[Vintage Merlot]

Re: Headlight questions...again

I bought two non-Ford replacements for less than $100 each on-line. They are identical to the originals provided by Ford.

[5bird7]

Re: Headlight questions...again

Buy the 03-05 headlights - they fit. The only difference is the style of the mount bracket where yours broke/fell apart - it's now ribbed. The only ones who will care about the change in style of bracket are those finicky OEM original showboats at some distantly future car show.

[jaguar72]

Re: Headlight questions...again

Thanks David, Roger and especially Dot,

Much appreciated...this is just a terrific forum.

I reordered the '03-'05 OEM Ford headlights.

I doubt if I'll live long enough to attend a "distantly future car show", Dot, so that part certainly doesn't matter at all.

Thanks again!

V/R,

Gary Jenkins/jaguar72

[steelblue5505]

Re: Headlight questions...again

Gary,
May I ask what the new a headlight cost?
thanks

[jaguar72]

Re: Headlight questions...again

Mike,

Sent you a PM with the details.

V/R,
Gary Jenkins/jaguar72

[Chuck]

Re: Headlight questions...again

Ok so I have to ask. Being relatively new to the 1st year of production one of them "looks" cracked and the other doesn’t. I've taken both headlight assembly's out to clean and expected the one that was cracked to fall off, it didn't. The NM only has 1,800 miles on it so maybe that's why the other isn't cracked. Curious why they need to be replaced, is it just because they’re cracked? Trying to keep the NM as original as possible.

[MATBird]

Re: Headlight questions...again

Chuck; any that I've seen were just hairline cracks that didn't necessarily need replacement, but if you took it to the dealer they did replace them. I'm sure others may have had worse than I've seen.
They did one of mine and wouldn't do the other since it was not cracked.

[jaguar72]

Re: Headlight questions...again

Chuck,

As you probably know, the 2002 headlights are held at the top by a bolt that screws into a threaded metal insert fitted inside the Bakelite (I doubt if it's actually Bakelite... it's a plastic or resin material) mounting boss which is part of the light case or "bucket". The resin material cracks around the threaded insert and then breaks off completely so you can't tighten the top of the headlight against the bracket. The light is then held in place only by the two removable clips, one on each side.

Functionally, does it really make a difference? I don't know but I think it allows more vibration and lets the headlight move around more than it should. It's also pretty annoying... . The new headlights are "improved" redesigned versions which apparently do not crack (please note I do not know this from personal experience). They use a threaded stud embedded in a ribbed (for strength and probably heat dispersal) boss and are held on by a nut and washer.

If you want to maintain originality I would think the 1W6Zs (please see my orginal post for the full part numbers) are the way to go. The supplier told me these are an improved version of the 2002 original, but I have not seen one to verify this.

Hope this helps a little.

V/R,
Gary Jenkins/jaguar72

[wtxbird]

Re: Headlight questions...again

I pulled the mounting hardware from the 02 headlights and installed them in the newer design if my memory is correct. Those 2 removeable clips are a bear to get out. I used Vise Grips and a lot of force to remove them and a hammer to get the clips back in tight. Anyways there is no movement.
My lights had that foggy haze on the inside. I used aftermarket ones and they are still like new.

[jaguar72]

Re: Headlight questions...again

Roger that. The clips can be a little difficult, especially the inner ones, but they will come out. They are spring loaded; i.e., a flat spring on the clip bears against the car bracket (ABS plastic) surface to keep them in place (the spring is quite sturdy but it can probably get distorted and cause problems...). The other side of the clip slides against the inner surface of the brackets molded into the headlight "bucket". Wiggling the clips back and forth (both side to side and front and rear) as they are extracted seems to help although there won't be much movement. On the inner ones I had to use a large needle nose pliers (i.e., one jaw through the hole on top of the clip; there is not much room to strive...). The outer ones came out by hand. A very little WD-40 might help. I used a small amount of mild lubricant on all the friction surfaces when I reinstalled them (I think I used vaseline) and it seemed to help. The bottom of the clips "home" against a molded stop on each side when installed correctly. The surface on the car bracket is, again, ABS plastic, so try not to use undue force when reinstalling the clips; actually you shouldn't have to; they should snap into place without too much force if the light "bucket" is lined up correctly, at least mine did. Be as gentle as possible on both extraction and installation...your TBird will appreciate it. I have had both lights out-and-in two times.

Hope this is helpful; it may not be typical of the "clip experience" others have had.

V/R,

Gary Jenkins/jaguar72

[Chuck]

Re: Headlight questions...again

Scott, I did the same as Gary - For the larger one I needed needle nose pliers on both. Gary, the main difference that I recall is that both the 02 and 03 - 04 are pretty much the same the difference being that the thing that cracks on the '02s is smooth, on the 03 - 04s it's got fins or blades. I would compare the 2 but the NM is asleep in its bag for the winter.

[jaguar72]

Re: Headlight questions...again

All,

FYI, Installed driver/left side Ford OEM headlight (3W6Z-13008-AD) this morning...it fit perfectly (as you might expect), slightly better than the original (although it was hard to tell since the bracket on the original was in pieces and could not be tightened...); it was also easier to install than the aftermarket number I tried a couple of weeks ago. The infamous clips both came out and went back in without difficulty (the inner with a needle nose pliers and the outer by hand; reinstallation was by hand only). The small amount of vaseline I put on all the clip friction surfaces seemed to help. Be careful when removing the inner clip, however; it is very close to the radiator sight shield and you could easily crack the sight shield removing the inner clip.

Note that the Ford OEM headlight assembly does not come with a nut and washer (neither did the aftermarket) for the mounting stud...it's a 6M x 1.0 nut and the stainless ones I bought were 10mm AF...I used a small brass washer over a larger nylon washer (for style points).

The Ford OEM lights do come with both bulbs (which they should considering the price).

I'm going to order the passenger/right side (3W6Z-13008-AC) this afternoon. These Ford OEM lights are not cheap but for me the precision is worth the loot; and they do have that tiny Ford oval on each lens... .

Once again, thanks for all the help...made things much easier.

V/R,

Gary Jenkins/jaguar72

[MATBird]

Re: Headlight questions...again

Thanks for posting Gary. Great info for potential future use