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Topic: Headlight replacement on a 91 U225 (Read 1064 times) previous topic - next topic

Headlight replacement on a 91 U225

Greetings everyone,

Those of us with older coaches generally have yellowed and somewhat opaque headlight lenses after all these years, speaking specifically of those coaches with the 87-91 Ford F-100 or Bronco headlights. While I'd like to do an upgrade, I have not been able to source an HID direct bolt-in kit for this model headlight. The universal kits don't appeal to me, as the local DMV may have their own interpretation of whether or not they pass inspection. Despite attempts to polish and clean the headlight lenses, in the end I decided to just replace both headlight assemblies.

I found a good source for these headlights here --> 1990 Ford F150 Truck Headlight at 1AAuto.com with how-to installation video. They include the chrome trim, come with new headlight bulbs, and a 3 year warranty.

When FT installed these new, they trimmed off part of the inboard support frames, pop riveted a piece of angle to the inboard headlight area of the fiberglass, and ran a self-drilling, self tapping screw in through the angle and headlight frame. These screws are accessible through the grill with a long bit or bit extension. The original mounts were used on both outboard ends of the headlight assemblies, although with different hardware. The headlights are pulled back and down from below once the fasteners have been removed. New ones install the same way.

I dreaded having to cut up new headlights, and thus immediately void the warranty, so it was decided to try installing them without cutting them up. And - they went in just fine. The only caveat is on the driver's side, the vacuum pump needs to be unbolted and moved a little to get enough room to get the headlight in place, then reinstalled. That's why they trimmed both support frames.

For the two outboard connections on each assembly, the installed studs need to be removed, and the hardware used on the old headlights reused. This consists of two long screws, four plate washers, and two nylon spacers (see pics). The longer spacer goes on top. One of the mounting points on the old headlights had been broken off because the screws were a little too long, so I added two washers at the head end to reduce the depth the screws penetrated.

Total time - less than two hours. Much easier than was anticipated.

The difference in appearance between old and new is very apparent. The difference in what I can see from behind the wheel at night is astonishing. It's not HID, but it is a major improvement in visibility.

Steve
1991 U225 Grand Villa

Re: Headlight replacement on a 91 U225

Reply #1 –
Few more pics...

As I'm moving back to Canada soon, I also need to have daytime running lights. I installed a pair of high power LED lights below the headlights with some outdoor butyl 3M double sided tape. Found them on ebay for $17, they are waterproof and feature SMD 5050 LEDs. Very, very bright. Each lamp draws only 60 mA. Ran the wires towards the firewall where other wires go through, fed them in, and connected the hot lead directly to the switched side of the ignition solenoid via a 2 amp inline fuse and a rocker switch, in case I just want to turn them off. Good to go.

Steve
1991 U225 Grand Villa

Re: Headlight replacement on a 91 U225

Reply #2 –
To quote Steve: "They include the chrome trim, come with new headlight bulbs, and a 3 year warranty. "

Steve,

Thanks for the link. However, while reading the description it says "Bulbs not included ". So, any suggestions as to your souce for the bulbs? Did you get them from 1A?
Don Hay
'92 Grandvilla, U-280
The Hayfever Express
Build #4055
'97 GEO Tracker
Life is like licking honey off a thorn.

Re: Headlight replacement on a 91 U225

Reply #3 –
Hi Don,

I read that description too, but on receiving the headlights I found new headlight bulbs were indeed installed. The marker light bulbs were not included. I just unscrewed the existing marker lamp assemblies and reconnected them to the new headlights.

I forgot to mention - remove the new headlight bulbs when installing the new headlight assemblies, then refit the bulbs when fastened.

And - here's a link to the LED daytime running lights I used (price has gone up to $21, with free shipping) - LED WHITE 2X SLIM DRL DAYTIME RUNNING LIGHTS FOG HID HEAD SMD POWER XENON /W13 |

Steve
1991 U225 Grand Villa

Re: Headlight replacement on a 91 U225

Reply #4 –
I fitted universal HID kits on my 95 - no drama and completely reversible. The U320 headlight location is so low I've never been flashed or bothered.
The selected media item is not currently available. Dave Head & Megan Westbrook
Titusville, FL - The Great Outdoors
'98 270 buying this month
Toad is a 2018 F150 XLT

Re: Headlight replacement on a 91 U225

Reply #5 –
Great job, Steve!!! And terrific photos, too. I do like the LED strip below the headlights. Thanks for doing such a good job documenting your work!!!

Craig
1993 U225 36' Unihome GV with PACBRAKE exhaust retarder, Banks Stinger and Solar Panels.
Toad: 1999 Jeep Wrangler 2-door soft-top.

"No one has ever had to evacuate a city because the solar panels broke."

Re: Headlight replacement on a 91 U225

Reply #6 –
Steve thanks for the great write up. I think this is on my todo list now...

see ya
ken
The selected media item is not currently available.ken & dori hathaway & Big Agnes
🍺1992 U300 GrandVilla WTBI #4150 FOT FBP 2011
✨6V-92TA DDEC Parlor Coach 350HP Series 92
🏁2011 Nissan XTerra Pro-4X

Re: Headlight replacement on a 91 U225

Reply #7 –
Thanks folks. It's a worthwhile upgrade. I've gone from a feeble yellow glow just in front of the coach to being able see a ways down the road.

Quote from: Dave Head –
I fitted universal HID kits on my 95 - no drama and completely reversible. The U320 headlight location is so low I've never been flashed or bothered.

I hear ya Dave. Not sure on the rules on those in Canada, and don't want to have a hassle registering the coach up there. Needed new headlights with clear lenses at the very least, so I may yet upgrade further down the road.

Steve
1991 U225 Grand Villa