while you have the headlights opened, it's better to upgrade the projectors to a much better HID projector. there's literally 4 screws holding the OEM one in, the EVO XR 2.0 are a direct line up to the OEM one. same high beam solenoid plug also.

once removed from the truck, remove the ballast, bulbs and wires attached to the ballast. there's a few metal clips/screws to also remove. heat up your oven to 240*. put the oven tray at the bottom, place the headlights on a cardboard piece. let them bake for about 8mins. remove with insulated gloves and start prying apart, slowly. I would use either a flat head or those plastic trim removal tools. you probably have about 5mins or so to work with it until it gets cold again. then back into the oven again for another 8mins or so. then start again. the best spot to pry with your hands to remove it is at the blinker area. it should take twice, maybe 3 times of going into the oven. it may get sticky from the current butyl.

follow this method.

 

I wish Ford used a better plastic like BMW does for headlight lenses. I've seen 20 year old beemer like my girls look brand new. Meanwhile I'm on my 2nd set of OEM factory Raptor headlights bought in great shape directly from Raptor owners and these too are yellowing from UV.

 

I like using the panel clip pliers from the local Hobo Freight to help pop open the headlights. If they are Permaseal instead of Butyl, you'll need 2 or 3 or more heat cycles to get it to release easy. The butyl sealed lights are easy peasy lemon squeezy to open.

https://www.harborfreight.com/panel-...ers-63699.html

 

Yeah the OEMS are permaseal and a pain in the buttocks. I nearly sliced my thumb off with a flathead trying to remove all of it from the channels.

 

Is your best recommendation to find a good set of halogen headlights to take the lenses from? Or does anybody have experience with aftermarket lenses such as these from Amazon?

 

it seems to have mixed reviews. Someone on there did the swap, you can see their photo on the review. As long as you get a UV PPF applied to it, I would think it would be fine. Again, the clips won't match up but they will still seal up if done properly.

 

Worst case, Amazon returns are always easy. I'll report back in like a month when I get some other projects done and am able to dedicate a day for this.

 

New user but wanted to chime in as I did this lens replacement on my 2013 Platinum.

• New Bulbs - Osram 66340XN2 Night Breaker 220
• Mishimoto Evo X R 2.0 Projector housings
• eBay $30 lens covers -
  • you will see everywhere that these are listed as not compatible with the HID housings. It is true that there are slightly different tab locations, but half of the tabs line up and half don't
  • The tabs don't interfere in any way with the reinstall, and I was perfectly happy with the result.

1. As noted, the Permaseal is a bear to work with. I have done lens replacements on butyl lights and it's a breeze comparatively. You will absolutely need to pry, and you will need to use some judgement to avoid marring the housings
2. Heat - bake them in the oven, pry for 4-5 mins and back in the oven. 220F was my temp I chose. You will need to do this many times.
3. Clean the channel - also required heat for me to be able to get the result I wanted.
4. Butyl - I used 3/8 in butyl, stretched thinner/thicker as I laid it into the channel to conform to the housing nicely. You will see there are areas that are wider/thinner and it will be apparent.
5. Now move back to your projector housing without the lens.
6. Evox R 2.0 projectors bolt in, be careful undoing the clip for the high beam cutoff solenoid - it will clip directly into the new projector so you don't want to damage it.
   1. I chose to take it out to my truck, loosely install and test the beam pattern. Easier to see if everything is working as intended before installing the lens.
7. ​​​​​​​If everything checks out - in my case it did - you can now pop the housing with the butyl in the oven to warm up and make it easier to secure the lens. You will also want to bend back the clips that do secure the lens and heat makes this a breeze.
8. Note - for the HID's you also have to swap over the shrouds into the lens. The mounting tabs are the same for these aftermarket lenses even though they say they're incompatible, I had no issue.
   
   Lens/Shroud Mounting
   
   Testing the Evo X projector in the open housing
   
   New Lens vs. Old
9. ​​​​​​​

 

very nice. it's a night and day different in output and cutoff. hope you get the lenses protected with a UV film so they can last.

 

Bookmarking this thread. The "process" definitely is not "easy" then. But not impossible either.

2006, original lens were cloudy. Sanding and repolishing was tedious, got much easier when I changed from the "parts store kit" for a drill to my (woodworking) random orbit sander and wet 200-400-800 .. .. to the 4000 grit. They do allow much better night vision now. (Need the replacement clear coat added, based on what others wrote above.)