2016 Sierra D5S Headlight Projector retrofit

Denali_Joe · November 12, 2019

Haven't had any luck finding any info on anyone swapping out the factory projectors in a 16 or newer Sierra D5S style headlight. My headlights got the jiggles, tried 2 after market D5S lamps, the most recent with the external Hylux ballasts. A few months back I bought the Fast Headlights kit, cut the back of one of my headlights off, only to discover that the factory projector has a shroud on it and wouldn't come out so returned the kit.

Plan is to bake them and install new projectors, bulbs, and ballasts. Was going to order this kit up from Phil again, same one I returned a few months ago:

https://www.fastheadlights.com/product-p/buy_d2s5_sierra_kit_hylux.htm

I know the adapter plates he sells with it will match up with the factory mounting and the solenoid for the brights will be compatible as well. Plus has a 4300k kit, I have 5500 today and too blue for me. Current Hylux ballasts have been money in the D5S kit I have in there now.

I would also like to swap out the halogen blinker for an LED, gonna need some resistors for that, any recommendation on a good LED that will outlast the truck?

Also planning on painting some of the chrome black. Gonna tackle this around the end of Dec when I have some time off to take my truck out of service for a day.

Any pointers for anyone that's done this headlight before?

DominatorZ71 · November 12, 2019

Days of resistors are over. Buy from LasfitLED.com

Denali_Joe · November 13, 2019

16 hours ago, DominatorZ71 said:

Days of resistors are over. Buy from LasfitLED.com

Thanks I'll check them out!

Denali_Joe · January 16, 2020

So, I got my hands on a junk headlight.

Tried with head gun and oven to get the light apart, I struck out. I was just destroying it.

So, I cut the back off. Used the oscillating cutter, hardly made a mess and it took like 2 minutes to do. Way better than the hot knife. When I do the ones in my truck this is how I will be opening them.

I removed the projector by taking out the 4 screws and unhooking the high beam connection and used a screwdriver to pop the shroud off of the projector. Must be the cheapest projector Germany ever made!

There was an adjustment screw on the mount for the projector, but couldn't figure out how to get it apart without breaking it.

So, I used my tin snips and cut the shroud so I could remove it.

I remounted the projector and there is a little gap, will have to see how big the gap is with a new projector, my guess is pretty similar, will have to figure out some shroud solution. I really think if I had to I could cut a new shroud to get it back in and on a new projector and glue it from the back and you would never see the crack in the shroud unless you get your nose right up to the housing, which I'd be fine with.

Now I'm off to find some projectors and shrouds and figure out how to mount them, leaning towards the mini d2s 5.0, definitely want a bi-xenon design. Going to order up some of those lasfit LED's for the turn signal too. Wish I could have gotten them apart to paint some of the chrome black, but pretty stoked that it looks like I'm going to be able to pretty easily swap out the projectors. Probably going to be another month til I get some parts and some mocking up done, but I'm gonna get this done.