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View Full Version : Fog lamp removal and resurfacing and air silencer removal



ratman1648
07-25-2006, 10:08 PM
This is a step by step on how to remove the stock air silencer,headlamps, and remove and polish the fog lamp lenses.

Here is the problem…. They are extremely pitted and dare I say it, foggy!
http://i39.photobucket.com/albums/e163/ratman1648/Before-off.jpg
http://i39.photobucket.com/albums/e163/ratman1648/Before-on.jpg

Here are the tools required including a 5/16 socket and 600 grit wet sandpaper up to 2000 grit (not pictured).
http://i39.photobucket.com/albums/e163/ratman1648/toolsrequired.jpg

And these to remove the air silencer including a 7mm nut driver and a 10mm socket w/ a 1-1/2 ft. extension.
http://i39.photobucket.com/albums/e163/ratman1648/Airchambertools.jpg

ratman1648
07-26-2006, 05:34 PM
Removal of air silencer chamber and headlamps

Now I didn't realize that DMAG had already posted a how to on the silencer removal (http://www.lxforums.com/board/showthread.php?t=11320)but I included my version as it is needed to remove the left side fog lamp.


1. Remove the 6 plastic rivets holding the top of the front fascia with the flathead screwdriver. The picture only shows 4 but there are 6.
http://i39.photobucket.com/albums/e163/ratman1648/topfascia.jpg

2. Remove the headlamp assemblies by removing the upper and lower 5/16 screws indicated here by the blue arrows.
http://i39.photobucket.com/albums/e163/ratman1648/P1020818.jpg
http://i39.photobucket.com/albums/e163/ratman1648/P1020819.jpg

To access the lower screw push down on the fascia just below the headlamp
http://i39.photobucket.com/albums/e163/ratman1648/P1020824.jpg



After removing the driver side assembly you will notice there is very little, in fact no room to remove the three philips head screws that hold the fog lamp assembly. The intake silencer wraps around the fog lamp leaving only about an inch or two to work with. I appologize for the clarity of this pic. The mass just to the left and rear of the fog lamp is the silencer.
http://i39.photobucket.com/albums/e163/ratman1648/Airabstruction.jpg

You can also see the threaded end of the 10mm bolt that holds the silencer indicated by the blue arrow.
http://i39.photobucket.com/albums/e163/ratman1648/P1020822.jpg

3.Remove part of the plastic underbody panels using the 7mm nut driver. Pull the panel to the side and you can see the bolt. Using the crazy long 10mm socket, remove the bolt then pull out the silencer. Replacing this is optional as I chose to leave it out. Here is the void left from the removed silencer. For more detailed instructions please GO HERE! (http://www.lxforums.com/board/showthread.php?t=11320)
http://i39.photobucket.com/albums/e163/ratman1648/Noairchamber.jpg

Here is the mass of plasic that is the air silencer
http://i39.photobucket.com/albums/e163/ratman1648/Airintakechamber.jpg

*****TIP***** When reinstalling the headlamps lightly tape the lower bolt to the nut driver so it doesn't fall off.*****TIP*****

ratman1648
07-26-2006, 05:35 PM
Fog lamp removal and resurfacing



1.Remove these three philips head screws holding each fog lamp assembly to the bezel. A stubby screwdriver works best.
http://i39.photobucket.com/albums/e163/ratman1648/P1020792.jpg

2. Disconnect the harness.!!!!!DO NOT REMOVE THE BULB AT THIS TIME !!!!!

3.To get a good surface, using 600 grit wet sandpaper (for more minor flaws use higher grit paper i.e.-1000 grit) sand the lens surface until smooth, keeping it under running water most of the time.
http://i39.photobucket.com/albums/e163/ratman1648/sanding.jpg

4. !!!!!REMOVE THE BULB!!!!!

5.Using the orbital buffer and Meguiar’s NXT wax, buff the surface until clear. If it still has some bad pitting repeat steps 2-5 with the bulb installed as to not allow too much water into the housing.

6. Be sure the housing and bulb are thoroughly dry BEFORE installing the bulb

7. Put it all back together! No surprises here.

Here is the finished product…LIKE NEW!!!!:popcorn: :beerchug:
Keep in mind this process can also be used on the headlamps. Just be sure to finish with a higher grit paper as you won't want ANY swirls or scratches on these.
http://i39.photobucket.com/albums/e163/ratman1648/After-off.jpg
http://i39.photobucket.com/albums/e163/ratman1648/After-on.jpg

ratman1648
07-26-2006, 06:43 PM
Repeat post

MikeEast
07-26-2006, 09:50 PM
Nicely done!

I was going to resurface mine, but they are a little too destroyed...

Mike

Duke
07-26-2006, 09:54 PM
Nice write up! Good information to know.

(glad you fixed the text size too:) )

ratman1648
07-26-2006, 11:51 PM
This is what Mlkcrtnz's fogs looked like...
http://i39.photobucket.com/albums/e163/ratman1648/P1020832.jpg

The plastic surface appeared to be "flaking" off as if it was a separate layer. In order to get these to look good I had to start the process with a drywall rasp(flat metal blade with lots of teeth) to remove all the flaking. Then moved up to 60 grit dry, 100 grit dry, 150 grit dry, 180 grit dry, 250 grit dry, to the 600 grit wet. Then of course the polishing with the Meguiars and buffer.


The results.....:pepper: :rock:



http://i39.photobucket.com/albums/e163/ratman1648/P1020833.jpg

mlkcrtnz
07-26-2006, 11:57 PM
I am pretty impressed with the results. I think the genesis of this idea was TopGun Paint & Body in Corpus Christi. He wet sanded the headlight lenses on my Mark VIII I just sold. He made them look brand new. This is good stuff.

bmartin9122
07-27-2006, 11:02 AM
Wow!

higshemi
07-28-2006, 05:05 PM
Thanks for posting Ratman.... I had some scuff marks on my headlamps and I used this process to take them all out. Now they almost look as good as new.

ZMagnum
07-28-2006, 05:23 PM
Great pics and instructions. Thanks. I was wondering if I could do this to my headlights. I don't have fogs. My headlights look really bad.

Would it be better to remove the headlights first? Also, I've heard you should only wet sand in one direction. Is that true?

PaulFix
07-29-2006, 12:27 AM
Those results are amazing, my buddy has black pitted headlights and now I may just swap and clean them up. Great write up..

ASU_Magnum
07-29-2006, 01:06 AM
http://i39.photobucket.com/albums/e163/ratman1648/Airintakechamber.jpg

jesus what is the point of that thing?

ZMagnum
07-29-2006, 04:16 AM
I'm not sure but it looks like an odd type of musical instrument.

http://members.cox.net/mfrieden3/airsilencer.jpg

ratman1648
07-29-2006, 04:28 AM
Thanks for posting Ratman.... I had some scuff marks on my headlamps and I used this process to take them all out. Now they almost look as good as new.

no problem:wink:

ratman1648
07-29-2006, 04:35 AM
Great pics and instructions. Thanks. I was wondering if I could do this to my headlights. I don't have fogs. My headlights look really bad.

Would it be better to remove the headlights first? Also, I've heard you should only wet sand in one direction. Is that true?
I'm not sure about the one direction thing but I do know if you want them to look their best you may want to use a grit paper that's even higher than what I used as the last round of sanding(if you do more than one). 600 worked ok but if you finish with something higher like 800 or 1000 grit the polishing process will take less time and will avoid any fine scratches. Also you may try a lite polishing compound instead or the wax. Final note, be careful not to take off too much material as I believe the headlamp lenses are not as thick as the fogs.

ratman1648
07-29-2006, 04:38 AM
jesus what is the point of that thing?
you know that awesome sound you get with a CAI? No silencer! This is supposed to have the same effect as the mufflers or resonators in the exhaust....kill that sound comming out of the intake. Or a better example may be a handgun silencer.

ratman1648
07-29-2006, 04:41 AM
I'm not sure but it looks like an odd type of musical instrument.

http://members.cox.net/mfrieden3/airsilencer.jpg
ya know if you talk into the round opening in makes you sound like you're on 'old time radio'

bmartin9122
07-29-2006, 10:50 AM
ya know if you talk into the round opening in makes you sound like you're on 'old time radio'

I now know that I am not related to you. You must have been a milkman baby.

ratman1648
07-29-2006, 12:58 PM
I now know that I am not related to you. You must have been a milkman baby.
you ass

ZMagnum
07-29-2006, 01:46 PM
I'm not sure about the one direction thing but I do know if you want them to look their best you may want to use a grit paper that's even higher than what I used as the last round of sanding(if you do more than one). 600 worked ok but if you finish with something higher like 800 or 1000 grit the polishing process will take less time and will avoid any fine scratches. Also you may try a lite polishing compound instead or the wax. Final note, be careful not to take off too much material as I believe the headlamp lenses are not as thick as the fogs.

Thanks. I will try it with Mother's Plastic Polish. It says on the bottle that you can use it with a polisher. Now I have to buy a polisher.

bmartin9122
07-29-2006, 02:12 PM
you ass

I can almost imagine you trying to play that chunk of plastic like a hyper-modern baritone or tuba. :mrgreen:

kevdupuis
08-06-2006, 10:46 AM
The only problem with sanding headlamp lenses is that any hardcoat and uv coating the polycarbonate has will be removed, albeit some Chryslers lens coatings that I've experienced were thin and soft. Removing the coating will allow the poycarb to abraid easier, it also allows uv rays to turn the lenses milky and degrade (turn powdery) without any coating to protect them.
If you do go the sanding and polishing route on the headlamps then you will need to use another type of coating to help protect the lenses. I've had some luck with clear coating cleaned and prepped lenses, you just have to clean and care for them as a painted part.
The previous two paragraphs pertain to the headlamp lenses only, the taillight and Charger side marker lenses are made from Acrylic which is a hard less flexible plastic than Polycarbonate but also makes them more prone to chips and cracks which makes it undesireable for expensive headlamps. There are other differences that factor in also.
I have not checked which material the fog lenses are made so I cannot comment on them since I seen them made from either materials depending on our customers requirements.
We actually make external lighting for Chrysler, Ford, GM, Honda, Mazda, Toyota, Aston Martin, Bombardier, Harley Davidson and others.

Sorry to get a little long winded about lenses.

bmartin9122
08-06-2006, 10:49 AM
two words:

Rock Blockers

ZMagnum
08-06-2006, 12:33 PM
From what I can tell there is no coating on the headlights but even so the polish I'm using says it protects against UV.


The only problem with sanding headlamp lenses is that any hardcoat and uv coating the polycarbonate has will be removed, albeit some Chryslers lens coatings that I've experienced were thin and soft. Removing the coating will allow the poycarb to abraid easier, it also allows uv rays to turn the lenses milky and degrade (turn powdery) without any coating to protect them.
If you do go the sanding and polishing route on the headlamps then you will need to use another type of coating to help protect the lenses. I've had some luck with clear coating cleaned and prepped lenses, you just have to clean and care for them as a painted part.
The previous two paragraphs pertain to the headlamp lenses only, the taillight and Charger side marker lenses are made from Acrylic which is a hard less flexible plastic than Polycarbonate but also makes them more prone to chips and cracks which makes it undesireable for expensive headlamps. There are other differences that factor in also.
I have not checked which material the fog lenses are made so I cannot comment on them since I seen them made from either materials depending on our customers requirements.
We actually make external lighting for Chrysler, Ford, GM, Honda, Mazda, Toyota, Aston Martin, Bombardier, Harley Davidson and others.

Sorry to get a little long winded about lenses.

boggart
08-07-2006, 10:27 AM
Why not just take the foglights out from underneath? That was the install process for my aftermarket fogs. Just dropped the belly pan, popped the few 7mm screws holding the bottom of the fascia and got to them from there. Easy Peasy.

ratman1648
08-12-2006, 02:21 AM
Why not just take the foglights out from underneath? That was the install process for my aftermarket fogs. Just dropped the belly pan, popped the few 7mm screws holding the bottom of the fascia and got to them from there. Easy Peasy.
well I didn't try that but this route keeps you off the floor...for the most part anyway

ratman1648
08-12-2006, 02:22 AM
The only problem with sanding headlamp lenses is that any hardcoat and uv coating the polycarbonate has will be removed, albeit some Chryslers lens coatings that I've experienced were thin and soft. Removing the coating will allow the poycarb to abraid easier, it also allows uv rays to turn the lenses milky and degrade (turn powdery) without any coating to protect them.
If you do go the sanding and polishing route on the headlamps then you will need to use another type of coating to help protect the lenses. I've had some luck with clear coating cleaned and prepped lenses, you just have to clean and care for them as a painted part.
The previous two paragraphs pertain to the headlamp lenses only, the taillight and Charger side marker lenses are made from Acrylic which is a hard less flexible plastic than Polycarbonate but also makes them more prone to chips and cracks which makes it undesireable for expensive headlamps. There are other differences that factor in also.
I have not checked which material the fog lenses are made so I cannot comment on them since I seen them made from either materials depending on our customers requirements.
We actually make external lighting for Chrysler, Ford, GM, Honda, Mazda, Toyota, Aston Martin, Bombardier, Harley Davidson and others.

Sorry to get a little long winded about lenses.
did you miss the part about polishing with high quality wax? :wink:

DaILLestWun
11-01-2006, 05:56 PM
So that box is pretty much the resonator right? Does it add any performance at all? Probably minimal...And does it sound better when taken off?

high888
11-01-2006, 07:35 PM
You fools, that's not a resonator, it's a discreet waterpipe installed by
the tweekers at the plant, in Canada. It also can be used as a polyurethane boda, or a bong. Come on. Get real.:doh:

ratman1648
11-01-2006, 07:40 PM
So that box is pretty much the resonator right? Does it add any performance at all? Probably minimal...And does it sound better when taken off?
Only a little louder on WOT without it. As far as performance, it can only hender; although I don't believe it does anything at all for performance one way or another.

ratman1648
11-01-2006, 07:41 PM
You fools, that's not a resonator, it's a discreet waterpipe installed by
the tweekers at the plant, in Canada. It also can be used as a polyurethane boda, or a bong. Come on. Get real.:doh:
WTF is that supposed to mean?

NAS T MAG
11-01-2006, 07:48 PM
two words:

Rock Blockers

Nope...3 words. Rock Blockers suck.

Don't get me started on this one again. Search all the Rock Blocker threads and make your own decision.

DaILLestWun
11-02-2006, 10:31 AM
Only a little louder on WOT without it. As far as performance, it can only hender; although I don't believe it does anything at all for performance one way or another.


Cool thanks!!

Rev.Hammer
11-02-2006, 11:44 AM
REALLY!?!?! KOOL!
puffpuffpass duuude~!!!!

boblom
01-19-2007, 12:41 PM
as far as polish goes I use flizt. It works wonders on my guns so I tryed it on my old concourse and it cleaned up those milky looking eyes. Good stuff been on the market at lease 20 years
:popcorn:

Bryali
05-14-2009, 03:46 AM
I'll deffinitely have to give this one a shot. Great write-up

Appleseed
05-17-2009, 07:54 PM
Flitz! I concur. I've been using that for, like you said, over 20 years. Awesome on pretty much anything metallic. I havn't tried it but because if the abrasives in it, it probably works on the lenses too.

armin922
08-06-2010, 11:04 AM
just did the air silencer removal. It does sound like a CAI..esp when the car is cold and just started it up first thing. It sounds like a vaccum cleaner under the hood. BTW thanks, great write up

Paradog
08-06-2010, 11:35 AM
nice write up, but the fogs are also accessible from the bottom by removing a few screws and pop pins

ineedangermngmnt
11-01-2018, 10:29 PM
Nice, thanks