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2004 Ford E-350 Series Van 400-series Lighthead Housing Installation Guide

March 25th, 2009 · No Comments

1. Following the vehicle manufacturers instructions, remove the radiator shroud, grill, headlights and turn signals. Then remove the plastic substructure that they are mounted to (Fig. 1).
2. While holding the housing (without lighthead) in the exact mounting location, mark the location of the two mounting holes onto the mounting surface. There is a small notch cut into the inside of the two screw bosses on the housing. Use the notch as a guide, make your mark, then (with the housing removed) measure and make the mounting holes 5-3/8” apart (Figs. 2 & 3). NOTE: Depending on what lighthead you are using with this housing, you will need to drill a wire hole. Refer to the lighthead manual for the size and location.

1. After checking all your measurements, drill appropriately sized mounting holes based on your mounting hardware. Also drill your wire hole(s) at this time.
2. Install the supplied rubber gasket to the top part of the rear of the housing as shown above. Make sure the gasket is mounted evenly on both sides.
3. Install the supplied Fastex grommets (Fig. 3) and attach the lighthead to the housing.
4. Apply Locktite® #242 to the supplied 1/4-20 X 3/4” Hex Head Bolts, and secure the housing (with lighthead) to the vehicle, then extend the wires to your power source.

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