Upgrading Headlights and Lighting on a Bullnose Ford Truck (1980-1986)

The 1980-1986 Ford F-Series trucks, affectionately known as the “bullnose” generation, are beloved for their classic style and rugged durability. However, the lighting technology of the 1980s leaves much to be desired by today’s standards. If you’re looking to improve the visibility, safety, and aesthetics of your bullnose truck, upgrading the headlights and other lighting components is a worthwhile investment.

This article will guide you through the process of upgrading the headlights on your bullnose Ford truck, exploring the different types of headlight options available, necessary accessories like wiring harnesses, and a brief how-to guide. Additionally, we’ll discuss upgrading other lights on the truck, including marker lamps, tail lights, interior lights, dash lights, and more. Finally, we’ll cover important considerations for choosing different types of lights and provide instructions for properly aligning your headlights.

The standard headlights on a Bullnose Truck or Bronco are size 7 x 6 / 5 x 7.

Why Upgrade the Headlights on a Bullnose Ford Truck?

Upgrading the headlights on your bullnose Ford truck offers several key benefits:

1. Improved Visibility

  • Modern headlights provide significantly better illumination than the stock sealed-beam headlights that came with these trucks. Better visibility means safer driving, especially at night or in adverse weather conditions.

2. Enhanced Aesthetics

  • Upgrading to newer, more stylish headlights can give your truck a fresh, modern look while still maintaining its classic appeal. LED and projector headlights, for instance, offer a clean and updated appearance.
3. Increased Safety
  • Brighter headlights improve your ability to see potential hazards on the road, such as pedestrians, animals, or debris. Additionally, upgraded headlights can make your truck more visible to other drivers.
4. Energy Efficiency
  • Modern LED headlights consume less power than traditional halogen bulbs, reducing the load on your truck’s electrical system and potentially extending the life of your alternator and battery.

Types of Headlight Upgrades for Bullnose Trucks

When upgrading the headlights on your bullnose truck, you have several options to choose from, each offering different advantages and considerations.

1. Halogen Headlights
  • Overview: Halogen headlights are an improvement over the stock sealed-beam headlights, providing brighter and whiter light. They are a direct replacement for the original lights and are relatively easy to install.
  • Advantages: Affordable and easy to install. Halogen headlights offer improved brightness and a longer lifespan than the original sealed-beam lights.
  • Disadvantages: While brighter than stock lights, halogens are not as bright or efficient as modern LED or HID options. They also generate more heat and consume more power than LEDs.
2. LED Headlights
  • Overview: LED (Light Emitting Diode) headlights are becoming increasingly popular due to their superior brightness, energy efficiency, and long lifespan. LEDs provide a crisp, white light that greatly improves visibility.
  • Advantages: Extremely energy-efficient, bright, and long-lasting. LED headlights consume less power, reducing strain on the electrical system. They are also available in a variety of styles, including projector and reflector designs.
  • Disadvantages: Higher upfront cost compared to halogen headlights. Some LED headlights may require additional modifications, such as a new wiring harness, to ensure proper operation.
3. HID Headlights
  • Overview: HID (High-Intensity Discharge) headlights produce an intense, bright light that is much more powerful than halogen bulbs. HIDs use a different technology that requires a ballast to regulate the voltage.
  • Advantages: Extremely bright and capable of producing a wide beam pattern, improving visibility in all conditions. HIDs are particularly effective for night driving and in low-visibility conditions.
  • Disadvantages: More complex installation due to the need for a ballast. HIDs can be more expensive, and not all housings are compatible with HID bulbs without modification.
4. Projector Headlights
  • Overview: Projector headlights use a lens to focus the light beam, providing a more directed and intense beam pattern. They are often paired with LED or HID bulbs for maximum brightness and efficiency.
  • Advantages: Improved light focus and beam pattern, reducing glare for oncoming drivers while providing better road illumination. Projector headlights also offer a modern look.
  • Disadvantages: More expensive than standard reflector headlights. Installation may require modifications to the headlight housing.

Accessories Needed for Headlight Upgrades

Upgrading to modern headlights often requires additional accessories to ensure proper function and reliability. Here’s what you might need:

1. Upgraded Wiring Harness
  • Purpose: Modern headlights, particularly LED and HID units, can draw more power than the original wiring harness is designed to handle. An upgraded wiring harness ensures that your headlights receive sufficient power and reduces the risk of electrical fires or damage.
  • Considerations: Look for a wiring harness that is specifically designed for the type of headlights you are installing. The harness should include relays and fuses to protect the electrical system.
2. Headlight Relays
  • Purpose: Relays are used to handle the increased electrical load of modern headlights, particularly HIDs and high-power LEDs. They allow the headlights to draw power directly from the battery, rather than through the stock wiring.
  • Considerations: When installing relays, ensure they are rated for the power draw of your headlights. A common setup includes one relay for the high beams and one for the low beams.
3. Ballasts (for HID Headlights)
  • Purpose: Ballasts are required for HID headlights to regulate the high voltage needed to ignite the gas within the HID bulbs. They ensure consistent and stable operation of the lights.
  • Considerations: When installing HIDs, make sure the ballasts are mounted securely and in a location where they won’t be exposed to excessive heat or moisture.
4. Anti-Flicker Modules (for LED Headlights)
  • Purpose: Some LED headlights may flicker when installed in vehicles not originally designed for LEDs. Anti-flicker modules smooth out the power delivery to prevent this issue.
  • Considerations: Anti-flicker modules are particularly important if you notice any flickering or pulsing in your new LED headlights.

How to Upgrade the Headlights on a Bullnose

Upgrading the headlights on your bullnose Ford truck can significantly improve nighttime visibility and driving safety. Here’s a step-by-step guide to help you through the process:

1. Preparation and Tools
  • Tools Needed:
    • Screwdrivers (Phillips and flathead)
    • Wrench set and socket set
    • Wire strippers and crimpers (if wiring is needed)
    • Electrical tape or heat shrink tubing
    • Wiring harness or relay kit (if upgrading)
  • Safety Precautions:
    • Disconnect the truck’s battery before starting the installation to prevent electrical shorts.
    • Ensure the truck is parked on a flat, level surface.
2. Remove the Existing Headlights
  • Access the Headlights: Open the hood and locate the back of the headlight assemblies. On most bullnose trucks, the headlights are secured by a metal or plastic retaining ring.
  • Remove the Retaining Ring: Use a screwdriver to remove the screws holding the retaining ring in place. Carefully remove the ring and set it aside.
  • Disconnect the Wiring: Gently pull the headlight forward and disconnect the wiring harness from the back of the headlight. Be careful not to damage the connectors.
3. Install the New Headlights
  • Prepare the New Headlights: If your new headlights require a different wiring harness, connect the upgraded harness or relay kit to the truck’s wiring. This may involve splicing wires or using adapter connectors.
  • Install the Headlights: Connect the new headlights to the wiring harness, ensuring a secure connection. Place the headlights into the headlight housing and secure them with the retaining ring. Make sure the headlights are properly aligned before tightening the screws.
4. Test the Headlights
  • Reconnect the Battery: Reconnect the truck’s battery and turn on the headlights. Check that both the low and high beams are functioning correctly.
  • Check for Issues: Look for any flickering, dimming, or other issues. If you encounter problems, double-check the wiring connections and ensure the relays and ballasts (if applicable) are working properly.
5. Align the Headlights
  • Properly aligned headlights are essential for safe nighttime driving. Misaligned headlights can reduce visibility and create glare for oncoming drivers. Here’s how to align your bullnose truck’s headlights:
    • 1. Park the Truck
      • Park your truck on a flat, level surface facing a wall or garage door, about 25 feet away. Ensure that the truck is loaded as it would be during normal driving (e.g., with fuel and any typical cargo).
    • 2. Mark the Wall
      • Use masking tape to mark the centerline of the truck on the wall, as well as the center of each headlight. The center marks should be at the same height as the headlights on your truck.
    • 3. Adjust the Vertical Aim
      • Open the hood and locate the vertical adjustment screws on the back of each headlight. Turn the screws to adjust the height of the beam. The top of the low beam pattern should align with the horizontal tape line on the wall, slightly below the headlight centerline.
    • 4. Adjust the Horizontal Aim
      • Locate the horizontal adjustment screws and turn them to adjust the direction of the beam. The center of the beam pattern should be aligned with the vertical tape line on the wall, directly in front of each headlight.
    • 5. Final Check
      • Test the headlights by driving on a dark road. Ensure that the beams provide adequate illumination without blinding oncoming drivers. Make any final adjustments as necessary.
6. Final Check
  • Test Drive: Take the truck for a test drive at night to ensure the headlights provide adequate visibility without blinding oncoming drivers. Make any final adjustments to the alignment if necessary.

Upgrading Other Lights on a Bullnose Ford Truck

In addition to upgrading the headlights, there are several other lighting components on your bullnose truck that can be improved for better visibility, safety, and aesthetics.

1. Marker Lamps
  • Overview: Marker lamps are small lights located on the sides of the truck that increase visibility, especially at night. Upgrading to LED marker lamps provides brighter light and longer-lasting performance.
  • Installation: Marker lamps are usually easy to replace. Simply remove the lens, swap out the bulb or the entire assembly (if upgrading to LED), and reinstall the lens.
  • Considerations: Ensure the new marker lamps are compatible with your truck’s voltage and wiring. LED marker lamps often draw less power, so an upgraded wiring harness may not be necessary.
2. Tail Lights
  • Overview: Tail lights are critical for safety, ensuring that other drivers can see your truck from behind. Upgrading to LED or modern tail light assemblies improves brightness and reaction time, which can be crucial in avoiding rear-end collisions.
  • Installation: Replacing tail lights involves removing the lens, disconnecting the wiring, and installing the new lights. LED tail lights often include built-in resistors to prevent hyper-flashing.
  • Considerations: Make sure the new tail lights are DOT approved for legal road use. Some aftermarket options may be brighter but not street-legal.
3. Interior Lights
  • Overview: Interior lights are essential for visibility inside the cab, especially at night. Upgrading to LED interior lights provides brighter, whiter light and reduces power consumption.
  • Installation: Interior lights are typically easy to replace by removing the lens, swapping the bulb, and reinstalling the lens. LED bulbs are a direct replacement for incandescent bulbs.
  • Considerations: Check the size and type of bulb needed for each interior light fixture before purchasing replacements.
4. Dash Lights
  • Overview: Upgrading dash lights improves the visibility of your gauges and controls, making it easier to monitor your truck’s performance at night. LED bulbs are a popular upgrade for dash lighting.
  • Installation: Replacing dash lights often involves removing the instrument cluster or dashboard panels to access the bulbs. This can be time-consuming but provides a significant improvement in visibility.
  • Considerations: Choose LED bulbs with the correct color temperature to maintain the desired look of your gauges. Some LEDs may be too bright or too blue for your preference.
5. Fog Lights and Auxiliary Lights
  • Overview: Adding or upgrading fog lights and auxiliary lights can significantly improve visibility in low-light or foggy conditions. LED fog lights offer bright, focused beams that cut through fog without causing glare.
  • Installation: Installing fog lights usually involves mounting the lights on the front bumper or grille and wiring them to a switch inside the cab. Auxiliary lights may be mounted on the roof, bumper, or grille for additional lighting.
  • Considerations: Ensure that fog and auxiliary lights are properly aimed to avoid blinding other drivers. Wiring should be done carefully to prevent electrical issues.
Cost and Difficulty of Replacing Headlights in a Bullnose Ford

Cost:

Replacing or upgrading the headlights in a bullnose Ford truck (1980-1986) can vary in cost depending on the type of headlights you choose, any additional components required, and whether you opt for a simple replacement or a full upgrade to modern lighting technology. Here’s a general cost breakdown:

  • Basic Sealed-Beam Headlights: $20 to $50 per headlight, for standard replacement sealed-beam units that match the original factory setup.
  • Halogen Headlight Upgrade: $40 to $100 per pair, for halogen bulbs and housings that offer improved brightness and visibility over stock sealed beams.
  • LED Headlight Upgrade: $150 to $400 per pair, for modern LED headlights that provide superior brightness, energy efficiency, and longer lifespan.
  • Wiring Harness (if needed): $20 to $50, for an upgraded wiring harness to handle the increased power demands of halogen or LED headlights.
  • Headlight Relays and Fuses (if needed): $20 to $50, for installing relays and fuses to ensure stable power delivery to high-output headlights.
  • Headlight Alignment Tools (optional): $10 to $30, if you need tools to properly align your new headlights after installation.
  • Professional Installation (if not DIY): $50 to $150, depending on labor rates and the complexity of the installation, especially if upgrading to LED or HID systems.

Overall, the total cost of replacing or upgrading the headlights in your bullnose truck can range from $40 to $700 or more, depending on the type of headlights you choose and whether you opt for professional installation.

Difficulty:

The difficulty of replacing or upgrading the headlights in a bullnose Ford truck is generally low to moderate, depending on the type of headlights and any additional upgrades. Key factors affecting the difficulty include:

  • Mechanical Skills: Basic mechanical skills are required for a simple headlight replacement, such as swapping out sealed beams or halogen bulbs. If upgrading to LED or HID systems, additional skills may be needed to install relays, wiring harnesses, or modify headlight housings.
  • Tools and Equipment: You’ll need basic hand tools such as screwdrivers and wrenches for most headlight replacements. If upgrading to LED or HID systems, you may also need wiring tools (crimpers, strippers) and a multimeter for electrical testing.
  • Time Commitment: Replacing standard sealed-beam headlights typically takes less than an hour. Upgrading to a more complex system like LED or HID may take a few hours, especially if wiring modifications are needed.
  • Potential Challenges: Challenges may include aligning the new headlights correctly to avoid blinding oncoming traffic, ensuring compatibility with the truck’s electrical system, and fitting larger or differently-shaped headlights into the existing housings.

Given the relatively low complexity, most DIY enthusiasts can handle a headlight replacement or upgrade with basic tools. However, if you are unfamiliar with automotive electrical systems or are installing a more complex headlight system, seeking professional assistance may be advisable to ensure proper installation and alignment.

Considerations for Choosing Different Types of Lights

When upgrading the lighting on your bullnose Ford truck, it’s important to consider the following factors to ensure you get the best results:

1. Brightness and Beam Pattern
  • Brightness: Look for lights with higher lumens for increased brightness. However, excessive brightness can cause glare for oncoming drivers, so it’s important to find a balance.
  • Beam Pattern: Consider the beam pattern of the headlights or auxiliary lights. A focused beam is better for long-distance visibility, while a wider beam provides better peripheral illumination.
2. Color Temperature
  • Cool White (5000K-6000K): Produces a bright, white light that is similar to daylight. Ideal for headlights and fog lights.
  • Warm White (3000K-4000K): Provides a softer, more yellow light. Suitable for interior lights and tail lights if you want to maintain a classic look.
  • Blue or Red (6000K+): Some LED lights come in blue or red tones, which can be used for accent lighting or to achieve a custom look. However, ensure that these colors are legal for road use.
3. Compatibility and Legal Considerations
  • Ensure that any aftermarket lights you install are compatible with your truck’s electrical system and are legal for road use in your area. Non-DOT-approved lights may be brighter but can result in fines or failed inspections.
4. Durability and Weather Resistance
  • Look for lights that are rated for outdoor use, with waterproof or weather-resistant housings. This is especially important for exterior lights like headlights, tail lights, and fog lights.
5. Power Consumption
  • Consider the power consumption of the lights you choose. LED lights typically draw less power than halogen or HID lights, which can help reduce the load on your truck’s electrical system.

Conclusion

Upgrading the headlights and other lights on your 1980-1986 bullnose Ford truck is a practical and impactful way to enhance visibility, safety, and overall driving experience. Whether you choose halogen, LED, or HID headlights, upgrading to modern lighting technology ensures that your truck is better equipped for night driving and adverse weather conditions.

In addition to headlights, consider upgrading other lighting components like marker lamps, tail lights, interior lights, and dash lights. These upgrades not only improve functionality but also enhance the aesthetic appeal of your classic truck.

By carefully selecting the right lights, ensuring compatibility with your truck’s electrical system, and following proper installation and alignment procedures, you can significantly improve your bullnose truck’s lighting and enjoy a safer, more comfortable driving experience.

If you want more specific information on Bullnose Ford Trucks, check out my YouTube Channel!

For more information on Bullnose Trucks and Broncos, you can also check out the BullnoseFord SubReddit or Gary’s Garagemahal, both are excellent resources.