2004+ Ranger Hella Light Install
Hella 500FF Light Kit
Socket Set (standard)
Small amount of ½” steel pipe
Two ½”, 2” long, bolts with washers, and nuts, I advise nylon threads.
Use the gloves when working around the fiberglass header panel. Grinding it without gloves cuts up your hands (personal experience). And remember to be aware of all electrics, don’t get electrocuted.
1)Take your “L” brackets and drill a hole in the center of the ends, about an 1¼” from the end. The hole should be slightly bigger than ½”. Then, on the other end of the same side, make another hole far enough from the bend in the brackets that the light can hang freely, as this is where it will be mounted. As seen in picture 1.
2)Remove the grille by removing the top four screws on the grille, and releasing the two clips on either side of the bottom.
3)Once the grille is removed, tape off or mark where you want the Hellas to go. Then find your grinder. Below the marked line, grind a small slit in which the bracket can slide through. Make sure the slit is right in the bend of the header panel. Slide the bracket through and drill your holes in the fiberglass header panel. Mount the bracket.
4)Remove the horn on the right side. Let this hang for now, you will remount this later on the bottom of the bracket.
5)Take the ½” pipe and cut two pieces that are about ¾” long. Put these onto the screws for the Hella mounting bolt. They will make the lights hang a little lower. Bolt the lights upside down from the second hole you drilled in the “L” bracket. They will not be upright just yet because you will need to grind a little bit off of the fiberglass header panel, as seen in pictures 1 and 2.
6)Mount the horn you unbolted earlier on the bottom the “L” bracket. This is because it will not fit if it remains where it is mounted from the factory, the new lights get in the way, picture 2.
7)The next step is to wire them. Go through and have the switches and relays done. When the time comes for the end wires to the lights, wire the black up just as you would normally. The best place to mount the ground is to the hood latch. Loosen each bolt, but do one at a time, as to not move the latch out of alignment. Put a 2-prong wire connector on the end of the ground wire. Then, when the latch bolt is loosened, slide the connector under the bolt and tighten it back up, as in picture 4.
8)You should have working mounted lights now, aim them and enjoy. Picture 5.
Thanks for reading.
By Morgan Miller (2004xlmiller)
here are some pictures from Clinton, when he did his setup. This would be applicable for 01-03
models. He has a Buggman modded fog switch. Thanks Clinton.