I've seen a few NBS, NNBS, and Silverado retrofit threads, but finding a 03-07 Sierra thread was difficult, specially one without using Denali headlights, so I thought i'd throw one together real quick since I just finished mine.
Bought some cheap smoked eBay reflector headlights and a set of Morimoto MiniH1 projectors.
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Things I also purchased and did while it was apart: Morimoto XB LED highbeam bulbs just so it can match some what and have an instant on, 4 Switchback 3157 bulbs and 2 3156/3157 harness to get rid of my DRL, resistors for all on mod, and T10/194 LEDs. Take a look at these Highbeam bulbs lol
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Anyway, remove the mounting hardware from the back of the headlights. I set the lights on the edge of my workbench and used a halogen bulb to get an idea where there center of the beam would be against my garage door and marked it with tape. Then I used a heat gun instead of the oven this time and it worked just fine. Apply heat on high to the housing not the lens for about 10 minutes trying to evenly distribute the heat and start prying where you can to get them to separate. Take your time because you can break the housing if you put too much force. Once apart take out the little reflector thing that goes over the end of a halogen bulb because its in the way and mount your projector just to find out thats not going to work.
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Now make approximately a 3" hole in the back of your new headlights.
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I didn't get any pics of me trying to adjust the headlights in the housings because I was a bit busy and only have two hands. I had a battery on my workbench that I rigged up to apply power to the ballasts and bulbs and tried to get the beam lined up with the tape I put on the garage door earlier. Once I got the rotation, horizon line, and elevation where I thought It should be I marked it with a marker for lining up later. Here are some pics. Ignore the different color bulbs in the first pic. Idk why the color is so far off of each other in this pic. Later on you see that they match much better.
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Lowbeam, ignore how crooked it is at this point
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Highbeam
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Once I got things where I thought they should be and marked off I used Quicksteel putty to secure the projector bowl to the housing itself, support the projector on the inside to keep things from moving and let it dry for about 5 minutes before plugging everything in again and doing some final tweaks while the Quicksteel was semi malleable. Then i put the projector shrouds on followed by the lens. To get the lens seated I just put clamps on the headlight and hit it with the heatgun all over again.
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This part probably wasn't NECESSARY, but It definitely makes it easier to change the low beam bulb. The mounting bracket on the back covers the hole for the low beam bulb. For a normal halogen bulb its not that big of a deal, but for the longer HID bulb and harness it's close. So I just cut it out.
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The rest is just wiring things up which you have instructions for in the box and aiming. Pretty simple job to be honest. Here are some finishing up pics I took showing the switchback turn signals and the DRL delete. I also didn't like how the outer turn signal 194 flashed at a different interval than the front turn signal 3157 so I rewired that as well. So now instead of going outside, front, outside front, they all flash in unison. Not the back wall of my house is roughly 30 feet from the front of my truck.
Low beam
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All on/Highbeam. I'll be hooking up some HID Fogs soon.
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Switchback function, quad front turn signal, DRL Delete
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Installed my new grill today too.
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And here's and outside pic against the house across the road. My driveway slopes up hence why the beam is hitting so high.
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I went out and drove around a bit and adjusted some more and frankly its perfect and soooooo much better than it was before. The beam cut off goes right under the windshield of even the smaller oncoming cars yet I can see perfectly down the road. The only thing I might try next is taking the mounting brackets off the factory headlights and see if they will mount on the ebay headlights because the drivers side is sunk back a little too far for my liking.
I think that pretty much sums it all up. If you have any questions feel free to ask.
Bought some cheap smoked eBay reflector headlights and a set of Morimoto MiniH1 projectors.
Things I also purchased and did while it was apart: Morimoto XB LED highbeam bulbs just so it can match some what and have an instant on, 4 Switchback 3157 bulbs and 2 3156/3157 harness to get rid of my DRL, resistors for all on mod, and T10/194 LEDs. Take a look at these Highbeam bulbs lol
Anyway, remove the mounting hardware from the back of the headlights. I set the lights on the edge of my workbench and used a halogen bulb to get an idea where there center of the beam would be against my garage door and marked it with tape. Then I used a heat gun instead of the oven this time and it worked just fine. Apply heat on high to the housing not the lens for about 10 minutes trying to evenly distribute the heat and start prying where you can to get them to separate. Take your time because you can break the housing if you put too much force. Once apart take out the little reflector thing that goes over the end of a halogen bulb because its in the way and mount your projector just to find out thats not going to work.
Now make approximately a 3" hole in the back of your new headlights.
I didn't get any pics of me trying to adjust the headlights in the housings because I was a bit busy and only have two hands. I had a battery on my workbench that I rigged up to apply power to the ballasts and bulbs and tried to get the beam lined up with the tape I put on the garage door earlier. Once I got the rotation, horizon line, and elevation where I thought It should be I marked it with a marker for lining up later. Here are some pics. Ignore the different color bulbs in the first pic. Idk why the color is so far off of each other in this pic. Later on you see that they match much better.
Lowbeam, ignore how crooked it is at this point
Highbeam
Once I got things where I thought they should be and marked off I used Quicksteel putty to secure the projector bowl to the housing itself, support the projector on the inside to keep things from moving and let it dry for about 5 minutes before plugging everything in again and doing some final tweaks while the Quicksteel was semi malleable. Then i put the projector shrouds on followed by the lens. To get the lens seated I just put clamps on the headlight and hit it with the heatgun all over again.
This part probably wasn't NECESSARY, but It definitely makes it easier to change the low beam bulb. The mounting bracket on the back covers the hole for the low beam bulb. For a normal halogen bulb its not that big of a deal, but for the longer HID bulb and harness it's close. So I just cut it out.
The rest is just wiring things up which you have instructions for in the box and aiming. Pretty simple job to be honest. Here are some finishing up pics I took showing the switchback turn signals and the DRL delete. I also didn't like how the outer turn signal 194 flashed at a different interval than the front turn signal 3157 so I rewired that as well. So now instead of going outside, front, outside front, they all flash in unison. Not the back wall of my house is roughly 30 feet from the front of my truck.
Low beam
All on/Highbeam. I'll be hooking up some HID Fogs soon.
Switchback function, quad front turn signal, DRL Delete
Installed my new grill today too.
And here's and outside pic against the house across the road. My driveway slopes up hence why the beam is hitting so high.
I went out and drove around a bit and adjusted some more and frankly its perfect and soooooo much better than it was before. The beam cut off goes right under the windshield of even the smaller oncoming cars yet I can see perfectly down the road. The only thing I might try next is taking the mounting brackets off the factory headlights and see if they will mount on the ebay headlights because the drivers side is sunk back a little too far for my liking.
I think that pretty much sums it all up. If you have any questions feel free to ask.
