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401 viewsBefore, low-beam.
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401 viewsThe repaired pin in place. Thin plastic washer goes between the gear (front and rear gears) and the case.
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400 viewsSame duct, just took the picture from the left side of the Bus. Wrapping this duct is likely the most difficult of all the ducts so go slow and think. I know the pictures aren't a huge help but they give an idea. I'm sure there's more than one way to insulate this loop.
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400 views
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400 viewsUpper triple tree removed. Use a 6mm Allen wrench to loosen all clamping bolts. Alternately tap the bottom of the clip-ons to walk the triple tree and clip-ons up. I used a block of wood positioned under the clip-on and tapped it with a rubber mallet -- just in case I missed the wood!
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400 viewsThis is how it should look when done. The hard part of this install has been completed!
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400 viewsIt may not be necessary but I wanted to make sure my ballast wouldn't move around so this is what I did. I cut a notch at the top and bottom of the hourglass brace that the zip-tie would neatly fit in to. This will keep the zip-tie from slipping and thus keep a firm hold on the ballast. A sharp X-acto knife will easily cut through the plastic so operate slowly and carefully.
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399 viewsOriginal AM radio.
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399 viewsClose-up of the left side of the breather.
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399 views
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399 viewsI placed a friction plate back in to measure the gap. I had to use an Allen wrench: 2.5mm. Not good. Max gap is supposed to be no more than 0.6mm!
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399 viewsDone! I used a piece of wire sleeve tubing (that black ribbed bit) to protect the power wires from rubbing against the zip-tie and hourglass brace. Most likely it's not necessary but while I was in there...just in case....
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398 viewsDave Hall can't bare to watch the Venetian blind install :-)
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398 views
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Side view, both lights covered398 viewsTop and bottom lights covered in lightest tint, LED not covered.
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398 viewsI tucked the headlight connector into the middle left side of the headlight, below the white headlight adjustment mechanism. If you adjusted the headlight vertical adjustment earlier this is when you will want to return it back to its original position, rotating it clockwise.
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Connecting the DRL LED array.397 viewsI used a hand drill with a 2mm drill bit (smallest I had) to carefully drill a pilot hole into the side of the relay box. The pilot hole is 7mm down from the top of the lip of the fuse/relay box. It's between fuses M20 and M27.
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397 viewsThe original OEM clutch.
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397 viewsFirst zip-tie installed. I waited on the second one so I could move the ballast a little while working on the electrical cabling. This just helps get the ballast out of the way and keeps it from moving around too much. You can now install the HID bulb and secure it.
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396 viewsIn order to remove the upper triple-tree the headlight needs to be removed and then the U-shaped ladder part that the headlight attaches to is then removed. Remove the two nuts at the bottom of the ladder then lift it up. Also, disconnect the headlight connector and put the headlight out of the way.
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