Replacing Headlights With LED Bulbs
Mar 1, 2025 | 01:32 PM
#1
Replacing Headlights With LED Bulbs
Awhile ago, I decided to replace my standard issue headlight bulbs with LEDs. I had a bit of a problem. The OEM boots that are there to help keep moisture out of the lenses. I ended up having to cut up the boots but even then it was not a great fix and I still ended up with moisture intrusion. Within a month of replacing them, the right side burned out but I could not get a replacement bulb so reverted back to the OEM bulb and boot.
Fast forward. In my searching of local bone yards came across a pair of 99 headlight buckets with lenses and as a real bonus, they both had LED bulbs installed but totally different from the ones acquired several years ago. These had an insert that was the same as three fingers as the OEM bulb and the LED bulb then slid into the mount and you did a slight twist of the bulb and it locked it in place. It also has a cooling heat sink and small internal fan. Attached is a small rectangular box about 1.2 x 2.5 x.5" with an attachment cable and plug to fit into the headlight plug. Only issue I am still seeing is there were no HL boots and finding boots is a bit tough. The ones I came across were from a 2000 and they are different from the OEM boots off my 98. They also have a bit different construction and part numbers are also different. My question is for those of you that have installed LED headlights. How do you seal up the back of the housing to help prevent water intrusion? Do the newer ones have a special boot that slips on and seals the assembly and allows for you to plug the lamp into its socket? Any suggestions are appreciated. My rig does not have a nice warm dry garage to live in during extended periods of non use, so I am getting condensation in the headlight lenses.
Thanks guys and gals
Fast forward. In my searching of local bone yards came across a pair of 99 headlight buckets with lenses and as a real bonus, they both had LED bulbs installed but totally different from the ones acquired several years ago. These had an insert that was the same as three fingers as the OEM bulb and the LED bulb then slid into the mount and you did a slight twist of the bulb and it locked it in place. It also has a cooling heat sink and small internal fan. Attached is a small rectangular box about 1.2 x 2.5 x.5" with an attachment cable and plug to fit into the headlight plug. Only issue I am still seeing is there were no HL boots and finding boots is a bit tough. The ones I came across were from a 2000 and they are different from the OEM boots off my 98. They also have a bit different construction and part numbers are also different. My question is for those of you that have installed LED headlights. How do you seal up the back of the housing to help prevent water intrusion? Do the newer ones have a special boot that slips on and seals the assembly and allows for you to plug the lamp into its socket? Any suggestions are appreciated. My rig does not have a nice warm dry garage to live in during extended periods of non use, so I am getting condensation in the headlight lenses.
Thanks guys and gals
Aug 31, 2025 | 07:27 AM
#2
Registered User
Joined: Dec 2015
Posts: 707
Likes: 72
From: Ontario, Canada
I have a suggestion, don't use LED bulbs in a halogen headlight bucket and blind everyone(most likely), upgrade the wiring harness to run higher wattage halogen bulbs using relays and Hella 60/100 watt bulb i think it is, the bucket does get warmer though so hoping it won't degrade the reflector, so far so good, 5 years in.
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