This writeup will be a step by step guide to swapping the bumper, grill, headlights and header panel from a 2005 - 2007 SuperDuty to a 1999 - 2004 model to update the appearance. Other than some better headlight performance, this is an appearance modification only.
A more economical option is to watch for a take-off (as I did) used from another vehicle. Ebay and your local Craigslist are your friends.
There are pieces of writeups on this swap here and there and a search of this very forum will lead you to several of them. I don't claim this is original, only more thorough, I hope, than other write-ups and I hope even a complete newbie can follow this. Three examples I know of:
It has begun... - Page 2 - F150online Forums
There is also a diesel mag short writeup out there, but nothing comprehensive.
1. There are several eBay vendors and others who sell modified grills and lights with the '05 - '07 appearance that will bolt up to your '99 - '04 without modifying or swapping the header panel. You can read about these in this forum and several people already have written this up.
2. There are, similarly, diagrams for cutting your '99 - '04 header panel to make the '05 style headlights fit instead of swapping in the new header panel.
3. You will have to change out your headlight and turn signal connectors. There are vendors, such as GOS racing (Headlight Conversion Harness
) and dfuser (http://www.dfuser.com/catalog/harness.php
), that sell harnesses you can use for plug-and-play on the new headlights instead of soldering, as I did below.
Caveat: If your parts don't include the connectors, then I highly recommend one of these kits instead of going to the dealer - they will flat rape you on price for the headlight connectors. I regret I don't have the factory pigtail part numbers - mine were take-offs and used.
1. Here is what we start with (apologies for the angle shot) - as you can see, I had already upgraded in the past to the 2003-style headlights.
2. Next, remove the old grill - 4 phillips screws on top and clips on the bottom. The second picture shows the bare clip so you can see how it inserts in the header panel.
3. See these dust shields directly under the turn signal? If your truck has these, you will need to modify them before installing the new lights. A Dremel or shears will work fine - we will come back to this step.
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