Your first step in the process is to remove the cover from the back of the headlamp housing. On the dual halo projector headlamps, this process is done by grasping the round cover and turning it counter-clockwise. The picture below shows the headlamp with the cover on. Notice the directions for opening and closing the cover. 

 

 

After the cover is removed from the headlamp housing, you'll want to remove the stock bulb. This is done by releasing the metal tab holding the bulb in place. The metal tab is circled in figure 2.1. Once the bulb is removed from the headlamp, use the needle nose pliers to remove it from the female connector. 

 

 

Next, you'll need to remove the black ground wire with female connector. This wire is circled in figure 2.2 and is removed by gently pulling it off the headlamp.

 

 

Now, take your needle nose pliers and firmly grasp the rubber bundle that is protruding from the headlamp cover. With force, pull the bundle through the opening so that you can separate the wires from the cover. Be careful not to pinch or cut the thinner blue or black wires running through the bundle while performing this step.

 

 

Figure 3.2 shows what is left after you've separated the wires from the headlamp cover. In the next step, you will be enlarging the hole in the cover (circled in red) to allow the new HID bulb wires to pass through.

 

 

In order for the HID bulb wires to pass through the cover, you'll need to take your dremel tool and enlarge the opening. On a slow speed, work the dremel tool to open up the exising hole. A good size will roughly be the diameter of a quarter. This will allow plenty of room for the ends of the HID bulb wires to fit through with ease.

 

After you've created the larger opening, you can install the new HID bulb into the headlamp and secure it with the metal tab. (just a reverse of step 2) Next, pass the wires through the enlarged opening of the headlamp cover as shown in figure 4.1.

 

 

Re-install the cover on the headlamp housing (a reverse of step 1) and use the rubber sealant to seal the enlarged opening on the back of the cover. As shown in Figure 5.1, you can overlap the sealant for an air tight fit.

 

 

The final step of the fabrication process will be to attach the additional HID power and ground wires to the power and ground wires you removed from the headlamp in step 2 & 3. The additional HID power and ground wires are shown in figure 6.1. Please note, the red wire is power and the black wire is the ground. This is important to take note of to correctly complete the next step.

 

 

Attach the red male wire to the blue female wire coming off the headlamp. Attach the black female wire to the black male wire coming off of the headlamp. These connections are made by simply plugging them into each other. You may need to crimp the female connectors to ensure a snug fit. Once the wires are secure, slide the clear sheathing over the connections. Figure 6.2 shows the correct wiring connections.

 

 

Congratulations! The fabrication of your projector headlamps with HIDs is now complete. Your final step is install the new headlamps into your Mustang and plug your connections into your ballast. You can now enjoy superior lighting coverage with a crisp cut-off line. Please note, that the preceding steps must be completed for both left and right headlamp.