Fog Light setup for a 2003 XL F250 Super Duty using the OEM kit.

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1 Fog Light setup for a 2003 XL F250 Super Duty using the OEM kit. Since the kit (1C3Z15200BB) for the series truck was not available anymore, I explored options to put a set of OEM fog lights on my truck. The kit (5C3Z AC) was available so I ordered one and began my research to see if I could make it work. My requirements were the OEM style fog lights, OEM headlight switch with fog lights and a minimum of cutting of the truck wiring harness. I found that the kit wiring harness actually works better than the earlier set. The 2005 kit contains the following: We will not be using A, B, C, or H in the install because those parts will not fit on the 2003 or earlier series truck. You will need a set of OEM L and R fog lights, the new switch with fog lights (1C3Z BAA) and 4 more of the short fog light screws (I)

2 (W S439). The wiring harness (E and F) probably could be ordered separately to save cost; I am researching if you can get it separately. I am going to use the install guides from both years trucks and insert actual photos of my install. There is a note here that I paid attention to. The previous kits for the 2003 trucks came with wire connectors and splices. The new version of the kit changed their thinking and went with soldered connections. I agree with their logic as I have never liked the crimp connectors. With this kit there are only 2 actual splices, one for power to supply the fog lamp relay to turn on and off and the other is the high beam interrupt for the fog lights. I elected not install that wire as I want the fog light to burn all the time but the process is the same for both. The other connections are to connect the yellow and black passthrough wires which are simple solder joints. Here are the wiring diagrams for both years kits. As you can see there is little difference in the wiring, 2003 wiring diagram

3 2005 Diagram: And the Pin out for the 2 harnesses for the headlight switch in the 2003 F250XL.

4 We will be using the C273a connector to work with the new headlight switch that contains the fog lamp function. Pin 2 is the power to the fog lamp switch which we will be tapping from pin 12 (brown wire circuit 14 power which is powered hot in park or run). The pin 5 (yellow) is the output to the fog lamp relay to turn it on and off, and pin 6 (black) is a ground wire to allow the fog lamp annunciator lamp to work. This is actually what makes the 2005 kit more desirable than the kit. The 2005 kit interior wiring harness comes with the proper wiring harness pin outs connectors to install into the existing head lamp connector (C273a). This allows for the proper OEM headlight switch with fog lights to be used rather than the auxiliary switch that was provided with the 2003 kit.

5 Interior harness installation This part was actually easy. I am going to paraphrase what I did (and you can look at the install manuals to verify the installation.). I removed the light switch, and took the connectors off the back. I then removed the cover over the fuse panel, and removed the 4 bolts holding the fuse panel in. I then fished the wiring harness into the headlight hole while routing the harness to roughly the location that I wanted to end up near the yellow and black wire at the pass through wire location. I then used a dental pick to pop the large headlight connector apart as shown below.

6 With the connector lock popped out, I then removed the Brown wire from the pin 12 position by using the dental pick. Note: look at the wire as you remove it to see the connector orientation, the twin tabs on the wire go opposite of the dental pick. They face toward the connector lock tab, away from my thumb in the photo.

7 I then proceeded to skin part of the wire to allow a soldered splice. I took the brown wire of the harness that did not have a connector on it and spliced it together with the brown pin 12 wire. This is circuit 14 power that will provide the fog light portion of the switch to run the relay and the lamp in the actual switch. Once soldered and the heat shrink tube placed on, I then returned the brown connector to pin 12 position. I then installed the wires of the fog lamp harness to the following positions. Brown - pin 2 Yellow- pin 5 Black - pin 6

8 Push the orange lock back in and that part is done. Plug the 2 harnesses back into the new head lamp switch and reinstall the head lamp switch. I then fished the wiring harness to a point where the fuses would be easy to reach under the dash and zip tie them along with the relay to a wiring harness

9 Next was the connection of the Yellow and Black wires of the fog lamp harness to the Yellow and Black pass through wires Zip tie up the harness out of the way and reinstall the fuse panel, fuse panel cover and the head lamp switch **** Important note... I elected to not connect the Grey/Orange wire of the fog lamp harness to the Grey/Orange wire of the main bundle as seen in the picture above. This will allow my fog lamps to run on low and high. The instructions provide details on how to accomplish this task if you wish to have it so the high beams disrupt the fog lamps Exterior harness/fog Lamp installation This part was also easy, just a bit of heavy maneuvering to get the bumper on and off. You just follow the directions for the wire routing from the 2005 manual. I made one change to the directions, I placed the fog light relay on the black bracket at the relays on the right inner fender rather than just zip tie it to the harness. I liked the look of that way of mounting. It is currently zip tied but will be getting a small bolt and locknut to hold it. Next was the soldering of the black and yellow wires to the pass trough wires and shrink tubed.

10 Next I routed the battery connection wire across the back of the wire holder and connected to the battery. I also tied down the fuse holder to the wire to hold it out of the way and secured. I am going to replace the white zip ties with blacks as I get to the store.

11

12 Remove Bumper and install the fog lights to the bumper as in the 2001 install instructions. My bumper already had the clips (C) installed so if yours does not you will need 6 of them. The routing of the wiring to the fog lights from the relay is just as the instructions describe in 2005 installation. It fits just like it should; I would not recommend the routing found in the 2001 instructions as I do not think enough wire is included to the fog lights.

13 Reinstall the bumper and plug the wiring harness into the fog lights as you install the bumper. The driver s side is rather difficult to plug in if you install the bumper as the small cooling unit (power steering?) prevents you from getting your hand in there unless you have small hands. Picture of Headlamp switch with fog lights on. on.

14 Picture of the outside with fog lights on. My Cost Breakdown Part numbers Fog lamp kit $ 90 5C3Z AC Sold 2005 Fog lamps -65 Sold 2005 Switch Fog lamps 69 ebay OEM L&R 2003 Headlight switch 84 1C3Z BAA 4 short Fog lamps bolts 6 W S439 Total spent on the project $143 (Does not include items shipping costs) Dennis Cotton

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