exexpat

I just bought the ML and it had cracked fog lenses so I replaced those and the factory fogs were terrible. Once I upgraded to the 2002-up projector headlights and Valeo HID kit, the fogs weren't doing anything.

I'm kind of a lighting fanatic, so I ordered the Osram H7, which are rebased H9 to increase lumens on high beams from 1500 to 2100 Lm. I also replaced the factory fogs with Hella 90mm low beam projector modules. They were almost a direct replacement and rallylights.com even sells the factory plugs and hardware (see blury pic below).

What I started with Osram + Hella

Test fitment

Factory plug

Finished product




The improved lighting on both fog and high beam is amazing and all components were <$180 shipped.

ClayJ

Nicely done. Nice report with pics. I've always liked Hella lighting....

55fanatic

NICE, Im having problems now with my fogs on the 55, I think Im going to look in to this, I have already spent about 90 on replacing one rusted out lamp, this would work much better, is the casing big enough to install say um an HID bulb in there? You know, if you were in to that sort of thing

exexpat

I am into that sort of thing, I just couldn't justify the cost after buying wheels, tires, headlights, fogs, HID kit, etc since buying the car 2 weeks ago. These are H9 lights, so the aftermarket kits are relatively low in supply. Actually doing HID with rebased bulbs would ease the installation, since the only clearance problems you have are with the bulb plug and 90 degree downward bend. Do it; they are amazing and cut-off is typical Hella projector. For $60 each, they aren't too expensive either.

55fanatic

did you have to take the bumper off to do the install? And can you give me some Part numbers? Or a Link? I can justify a new fog light system and eventually HIDs, lol Also are they wired to the stock switch? I would desperately LOVE to be able to get them to turn on from the stock switch with just the parking lights on and not low beams!!!

exexpat

Lights can be found here: http://www.rallylights.com/hella/90mm_modules.asp.

You'll need 2 HL68137 and 2 HL87193. I made 3/4" brackets to mount like the factory lights from the top center using the factory allen bolt and the top centered screw on the light's lens assembly:



I'll look into the switch modification. If it is relayed like I think, then I can jumper the switch illumination wire to the switched lead and cut the current switched lead (i.e. only parking lights need to be on for it to work and they do not switch off with high beams).

55fanatic

you take any shots of your bracket?

55fanatic

and for the relay jumper I was thinking of changing the pin(on the relay) to link to parking lights instead of the 12V signal coming from the low beam head lights... except with the winter here its a bit too cold for me to play around outside

exexpat

It is just standard car stereo metal backstrapping using 2 holes (3/4"). I increased the diameter of the second hole to accomodate the 6mm threading of the factory allen bolt. Nothing too glamorous to show there.

So you have an ML55 without a garage? Shame on you!

55fanatic

I have a garage, it houses some other prized posessions... Like dad's 65GTO, his 56Harley, HIS daily driver(86 260E), and most of the time for winter, My supra... this year we might move his other cars in a 53 MB E limo and 73 cougar cobra jet.

Im driving an "suv" to him, lol Of course it should stay outside...

I have plenty of that backstrapping, shouldnt be a problem then. THANK YOU FOR MY NEXT PROJECT!!! How was the H9 bulb? How would you think it is? I might leave it temporary till I get an HID kit in there

exexpat

It's a good bulb with a very high lumen output (2100, compared to 1000 for an H4, or 2900 for a D2R HID). The thing you'll need to do is trim down the wide clip on the bulb base, so you can get it in 90 degrees off vertical (bumper core clearance). Since the filament runs front-to-back it in no way affects performance.

55fanatic

AWESOME!!! doesnt seem too complicated then and it seems to be 2/3rds of what my HID bulb is(maybe even a little less cuz of my ricey 8000k should be at lighting up those hard to see things...

If you should have time and figure out the way to by pass the relay in order to make the Fogs work with parking lights, PLEASE share

exexpat

Actually your 8000k means degraded performance for lumen output, so you should only have 2500 lumens now and the H9 will be quite close (84% of your headlights). I'll keep you posted on the relay modification for wiring. I'm an old hat at this kind of stuff (in case you didn't notice).

55fanatic

thats why I refered to my bulbs as ricey, they were the only ones I could find ANYWHERE that didnt entail me ordering them, as only one bulb worked at the time of replacement.

And should I have had enough time I would figure out the light setup but prolly would not do anything about it. My family also owns a repair garage and I am MECP certified(Mobile electronics) but knowing how to do something is different from actually doing it!!! With your help it should be able to get done!!!

One thing I was thinking about your strapping suggestion, I wonder if that will rust? Those arent made of the highest grade metal and they are also not meant to be located outside in the elements

55fanatic

PS I think we are the only ones who care about ML fog lights, lol

ClayJ

No - I'm taking notes...LOL. But I always have someone else do it for me(!)

exexpat

They should be ok, but I live in the no salt part of the country . Funny how the stereo guys are similar. I used to compete in '95-'97 with my Golf.

Dual Alesis MEQ230 and reconstructed dash with ID CD2 Comps:


Carver/KLW Broadway Amps completely hidden in the rear seat, IDQ10's glassed into the rear side panels (no trunk consumed and Carrera 2 spare tire):


And an outside photo for good measure:


The current commuter: Volvo 850 with much lower attention to detail (ML belongs to the wife):

55fanatic

I like that... that was what I wanted to do with my supra, except it has 50/50 folding seats in the back, also once I cut out the steal frame of the seat I wasnt sure how to keep its rigitity when somone sat in it or if the seat would continue to hold

ClayJ

exexpat-Even with all of the other cars I have, I'm still keeping and driving my 854 (heavily modded, of course).

55fanatic

I keep coming back to check out the Vdub, looks nice

And the volvo, is that an R? I think the body kit on that is pretty clean)I dont know volvos all that well, I dunno if the 855 is the R)

And I think I came up with a solution to anti rusting... just paint the brackets once I fit them. I used this Zinc based paint the other day for coating unpainted metal. Suppose to prevent rust up to 30 or 40% more then regular paint, but looks like a primer gray. Might paint it with that then paint them with a coat of black krylon and a coat of clear, that should do the trick... Ill prolly even melt some hot glue after and dip the ends where the screws will pass through the ends to make sure the metal has a nice rubbery cover so when the screw goes in, it doesnt chip the paint.

55fanatic

bump, finally ordered my projector fogs... also going to order a set of xenons to install with them...

fkong777

Nice find on that projector pod. How do you open that fog light cover. Mine doesnt move at all. I didnt want to use too much force and break the taps.

Looks like a great replacement. My fogs are pretty useless compare to the OEM HID.

55fanatic

for the trim ring you just gotta be Gentle... and it pops out... for the trim ring around the fog light you need to twist... its not difficult but sometimes they get stuck a little

edit: I snapped a few pics for you Fkong... as soon as Im done working on the car today Ill post some pics for you

-Pete

55fanatic

here are the pics of the fogs... I started test fitting the fogs in place today... this isnt going to be so easy with the bumper on... but Ill make it work... Going to try and pick up a 3000k ion yellow HID kit tomorrow...

Fkong here are your pics of the outer trim...

fkong777

Thanks. looks like it calls for that wedge tool. AKA screwdriver wrapped with paper towel