Yes, the heat seat sink on the back of the housing. It is not possible to get just a headlight off, you have to take almost the entire front end off to get to the one bolt on the headlight. The bolt is right by the fender flare so you also have to pull the wheel liner off to get to the headlight.
Sounds like a modern car to me, they really enjoy making the headlights impossible to easily remove for some reason. You wouldn't happen to have the original one that you broke still laying around would you?
Wow this is the most detailed work I’ve seen. Now that I see the light pipe situation it seems really doable. I design custom PCBs and work in lighting. With some proper dimensions and specs I may be able to recreate this PCB with amber LEDsAlright, so I went ahead and pulled the lights out of my truck and am trying a few options out for us. Firstly, here is what the boards look like for us. It's significantly different to the overseas options as previously discussed, but looks simpler in terms of circuitry. Its probably possible to change just the LED if you have access to a hot rework setup, but otherwise it's not happening with a regular soldering iron
It's attached using 3 bolts to the back of the housing and a single cable as shown below. The connector seems like it'd be pretty fragile and there's really no way of getting to this without pulling the headlight completely, which is not a small feat. You can also see here the four light pipes used for the DRLs, and they line up with the 6 very small LEDs that shine into them from the board. The heat sink seems to indicate that these are all driven using 12v, but that was not verified.
Using an LED flashlight of similar whiteness to the DRLs, I lit up the light pipes with strips of kapton tape on only the upper section. This was put directly onto the light pipe surface itself. The result was a very yellow DRL that wasn't really what I was hoping for. The tape itself seems very amber on the roll, but once it is actually used it the tape is definitely yellow.
Next we held an amber turn signal bulb over the bottom section of the light pipes. This is significantly closer to the amber lights on the rest of the Raptor family. We left the kapton tape on the upper section to show the difference in hue. The brightness difference is not real, the flashlight was struggling to illuminate both sections at the same time.
The next steps are to find a film that can be placed over the light pipes permanently. I currently have on order an orange/amber film intended for window tinting, which should arrive in a couple of days. We had considered using translucent amber model car paint, but I'm worried that they won't last over time. I'll keep you all posted on the results.
It looks like they're made by Koito, which a quick Google search says they're a Japanese company that specializes in lighting and vehicle electronics (makes sense to me). I was wanting to take the board off the heat sink as well but I don't have enough thermal compound in my computer hoard box to re apply it unfortunately. I like where your head is at, I'll have to see if I can find a contact to message over there
I'll see what I can drum up for you, it almost looks like the circuit is a simple 12v+ and ground to the LEDs and then some sort of analog "hey I'm plugged in" circuit that goes back to the headlight controller. I'll take some more detailed photos of the board in the morning
Yeah I recognize most of the circuitry. Based on what I’m seeing though it looks like the voltage may be higher. If I’m reading this right the string voltage is closer to 18V (6 LEDs and ~3V per led) which means they are doing some sort of boosting going on. Looks like there is an NTC for temperature measurements as well as power and ground for the NTC. Overall I would say with some caliper measurements and some multimeter probing I remake this pretty easily
Here's a view of the rear of the aftermarket assembly posted above showing the wire connections, curious as to if they are similar to the ones when you took yours out?
That's probably a negative, there's only one plug from the truck's harness to the back of the headlight for the Raptor. Not sure if it's the same for any of the other models, but I'd imagine there would be some difference with the reflector style
