2001 Headlight Install for 99-2000 (AtomicInternet)
This procedure will void your warranty on your Cougar and could cause lots of bad things to happen.
Perform at your own risk.
First we'll look at the differences between the 1999 and 2001 headlights.
The 2001 headlight was made deeper and taller. I'm assuming to accomodate for a longer focal point.
For some reason the retaining bolt (indicated below) was moved from it's original position. Be aware of this when you try to fit the light in after cutting the frame. Sometimes you have to remove the plastic clip and/or bore out the hole this bolt fits into for the light to fit.
Now for the required modifications
Because the 2001 light is taller, you have to cut out the upper lip of the headlight cavity. We did this with a Dremmel and went through about 5 metal cutoff wheels. This is 3-ply metal welded together, so plan to spend an afternoon cutting it out. MAKE SURE YOU TUCK ALL WIRES/CABLES OUT OF THE WAY BEFORE YOU START CUTTING!
The best approach is to cut a little, try fitting the light, note where it's sticking, and cut some more. You'll never get a PERFECT fit, but you should get to a point where it fits in securely.
Finally, take the 99 turn signal bulb from your old 99 headlights and screw them into your 2001 lights. For some reason they switched the prong setup (see below) and the 2001 bulb won't plug into the 99 harness. You have to cut off one of the tabs from the 99 light to get it to screw into the 2001 assembly. (still holds secure)
And the results, thanks to PuckPuck's patented dust mask and MC-NECO:
Results after 12,000 miles:
Result Pic 1 Result Pic 2 Result Pic 3 Result Pic 4 Result Pic 5
Perform at your own risk.
First we'll look at the differences between the 1999 and 2001 headlights.
The 2001 headlight was made deeper and taller. I'm assuming to accomodate for a longer focal point.
For some reason the retaining bolt (indicated below) was moved from it's original position. Be aware of this when you try to fit the light in after cutting the frame. Sometimes you have to remove the plastic clip and/or bore out the hole this bolt fits into for the light to fit.
Now for the required modifications
Because the 2001 light is taller, you have to cut out the upper lip of the headlight cavity. We did this with a Dremmel and went through about 5 metal cutoff wheels. This is 3-ply metal welded together, so plan to spend an afternoon cutting it out. MAKE SURE YOU TUCK ALL WIRES/CABLES OUT OF THE WAY BEFORE YOU START CUTTING!
The best approach is to cut a little, try fitting the light, note where it's sticking, and cut some more. You'll never get a PERFECT fit, but you should get to a point where it fits in securely.
Finally, take the 99 turn signal bulb from your old 99 headlights and screw them into your 2001 lights. For some reason they switched the prong setup (see below) and the 2001 bulb won't plug into the 99 harness. You have to cut off one of the tabs from the 99 light to get it to screw into the 2001 assembly. (still holds secure)
And the results, thanks to PuckPuck's patented dust mask and MC-NECO:
Results after 12,000 miles:
Result Pic 1 Result Pic 2 Result Pic 3 Result Pic 4 Result Pic 5
