can you update to new style headlights and grill?
 

Noob with a question.

I just bought a 03 1500 express. It has the small square head lights, but first year for the newer style front end.I have see a ton of other 2003 now that have the newer style head lights and not the small one like ours? I used the search function but no luck. Can I just change out the grill and lights?

Thanks

Bump. No one knows if the chrome grille is directly compatible and quad headlights have the wiring present for plug'n'play?

comp headlight conversion
 

see my response to this on the earlier model years.

the wiring is different and you will need to do some alteration. well worth it in my opinion.

https://chevroletforum.com/forum/express-g-series-vans-30/front-clip-swap-39307/

of course u can change the headlights and grills. but tale help of a dealer. to get compatible parts check amazon.

I thought I would update this thread. It does appear that the different front ends can be swapped rather easily. Mine is a 2005 cargo van. Parts needed:

- Grille
- Composite (quad) headlights
- Radiator support for composite headlights
- Wiring harness for composite headlights

I'm electing to swap out the radiator support which presents a bit of extra work. Lines for the A/C and the transmission cooler pass through cut-outs in the support so the A/C needs to be evacuated and the transmission may need to be drained before those lines can be disconnected. I have everything except the Composite light wiring harness that I'll probably need to buy at the dealer.

Does anyone have a part number for that wiring harness? I'd like to avoid the dealer prices if I can.

Thanks!

Most salvage yards will sell you that harness for 20 bux or less in our area.

It's worth the time you take to go and get it as you may find other items to upgrade your van. Of course, that's easy to say for an old retiree.

Try a mass Craigslist search by typing a google search like: 2005 Chevy Express Van Parts site: craigslist.org

My total swap over cost for the grille, headlights and bumper was a whopping $210 cash. 1 hour at the wrecking yard in Mason, MI plus 1 hour in the driveway to cut and assemble.

Good luck with your conversion. BTW, getting new extruded nuts for your conversion is smart if you are in a salty winter environment. Trade Fastener in Redford, MI has these in stock if you cannot find them locally.

Who in hell wants a dealer to help? Too expensive and I believe this forum is more of a do it yourself venue.

2003-11 Express Headlight Conversion
 

Actually this is a simple swap. I bought my parts from CERTIFIT.com. I purchased (1) RH Composite Headlight Assembly complete with light bulbs, (1) LH Headlight Assembly complete with bulbs about $45ea., (1) Chrome Grill assembly about $85.00, (2) 9005 headlight socket @ autozone $6.00ea, (2) 9006 headlight sockets $6.00ea.
I removed old sealed beam headlight bulb/buckets, turn signals, grill and hardware. I reused all clips/bolts from grill and installed on new grill including Bowtie emblem. I then cut off sealed beam sockets and using wire connectors installed (2) black wires from each new socket (9005 high beam and 9006 low beam) and crimped on existing black wire from harness and installed remaining wire from each socket and installed on remaining green/yellow wires on harness. Should be a yellow wire and green wire, test which is low/high beam and crimp onto new sockets. NOTE: You DO NOT have to remove core support. The factory sealed beam ABS plastic has a faint line surrounding the round hole. This can be cut out using a dremel tool. Be careful not to cut anything behind the support. You can go to CERTIFIT (check to see if one is local) and take a picture of the composite headlight core support and use it as a guide for the cut out, that is what I did. After cutting is finished, connect new sockets to preinstalled light bulbs, install speed nuts in corresponding holes in core support, slip lower tabs of headlights into cut out slots in existing core support and insert 2 screws into speed nuts in upper headlight holes on core support. Snap grill into place and reinstall (2) bolts in upper grill and (2) bolts behind turn signal assemblies and reinstall turn signal assemblies. DONE!

I forgot to close this thread out. The swap was completed earlier this year. The grille was a bit more than quoted above but the light housings were right around $50/ea. The are no salvage yards that are conveniently close and I didn't want to screw with soldering new connectors onto the existing harness, so I bought a new harness through GMPartsDirect.com. Then I did as described above leaving the existing radiator support in the van, using a Dremel to follow the raised outline to make the composite lights fit and buying some speed nuts and stainless hardware to bolt the housings in. I reused some of the connecting hardware from the existing grille. Overall, it wasn't terribly difficult. Now I have a raditor support for composite housings and a sealed beam grille I'm trying to sell without much luck (I had already purchased the support).

Before
Attachment 12635

After (also showing 1" body lift and Offroad Warehouse light bar [for Silverado] installed)
Attachment 12636

Attachment 12637

I have my eyes set on anExpress very much like yours, except a different color. Thanks for the thread; this will be useful information.

Hopefully i don't get flamed as this is my very first post. Sorry for resurrecting such a old thread. I just picked up a 2009 Chevy Express 2500 Cargo Van as i do mobile Auto Detailing. One of the first things i noticed was the crappy headlights as they were sealed beamed headlights. I have been searching for a little while prior to actually purchasing the vehicle about how to get rid of them. I have now had the van for about 3 days and i tried searching one last time and stumbled on this thread. Does anyone have a master list of things needed to change the sealed beam headlights out? Maybe websites & part #'s of some sort. I live out in Hawaii and most of our base yards have closed over the years. If anyone maybe has some extra parts floating around that would aid me in doing this swap that would be greatly appreciated. Hopefully i'll get a little help as i'm new to Chevy's. Thanks

You have 2 options and I tried them both:

- replace the sealed beams with Hella sealed beam conversions

or

- replace the front end (like I did)

At first I tried the Hella sealed beam conversion kit. It is a housing that directly replaces the sealed beam headlamp except it uses an H4 bulb that come in many different options for output. If you just want to increase output and keep the same grille, this option runs a little over $100 and takes all of 15 min. to do - Hella 200mm H4 Headlamps

I had these for a bit and was very happy with the performance. It was a night vs. day difference. But I wanted the nicer looking front end.

To upgrade to the nicer front end, you'll need:

- the nicer grille
- the composite headlamps
- composite headlamp harness
- assorted fasteners and u-nuts with matching threads

You DO NOT NEED to replace the radiator support. After looking closer, the radiator support you have is the same one GM uses for the composite front end. If you remove everything and look closely, there is a raised outline of where to cut. I outlined the areas to be removed in yellow in the pic below. Fluid lines for the transmission and radiator pass through the support with no good way to deal with them other than disconnecting them entirely. I decided that draining fluids was going to be too much trouble so I got out the Dremel and started cutting. I swapped a few of the clips over but the new grille uses some different attachment points. You'll have to measure and make a trip to a good hardware store and get creative. I didn't record what fasteners I bought but it involved standard threaded fasteners and u-nuts that matched. The spring clips you swap over will hold the grille in place well enough to get a good sense of what you have to do.

Sorry I don't have a formal write-up. It was freezing outside when I did this so pausing to take pics wasn't in the cards. I just wanted to get it done. I do still have the radiator support for the composite headlamps that I'm looking to get rid of. If you want to update your front end and do a complete swap of the support, PM me. However, the shipping may not be worth it to get it from MA to HI.

Attachment 12170

Here is a better pic. Top with the yellow outline is a sealed beam radiator support. Bottom of the pic is radiator support for composite headlights. Note my outline vs. the area cutout:

http://i4.photobucket.com/albums/y13...n/IMG_1582.jpg

Attachment 12171

Thanks for the quick reply. To bad us didn't have a formal write up but I appreciate the help and photos. So how did you like the h4 conversion? That was my initial plan and then I read some place that people said you needed to change the wiring as the h4 bulb doesn't just plug into the stock harness. I'm glad I found this forum. The composite Headlamps are sweet but being in Hawaii it may not be worth it. The Headlamps aren't a problem it would be sourcing out the grill that would be the hardest.

I may end up doing the h4 conversion for now as the composite lamps suck. There are other brands out there with plastic lenses vs the hella glass ones, what do you think?

The H4 conversion I linked above plugged directly into the factory harness so I don't know where the people you have spoken to got their information. I don't recall doing anything to the wiring.

Glass is technically superior for transmitting light but plastic will withstand hits from road debris. Plastic will become UV damaged from the sun (possibly a concern for you in HI) while glass will not. If you are not someone who tailgates in traffic and you're not on roads where the front end takes a beating from sand, stones, etc., the glass will perform best.

Good points. I do headlight restoration myself. Glass would be best. I found a h4 conversion set with bulbs for like $50 for the pair. This may be the best route to go for my situation. Maybe down the road I can slowly source out the parts to make the swap like some of you folks did on here.

Can this be done on a 2002 Chevy express? I want to upgrade to a 2003 front end Sealed beam or composite headlights Doesn't matter. Just want the updated look. I want this http://images.craigslist.org/5N25Ke5...0db6a4102e.jpg
To look like this http://www.use.com/images/s_2/2006_C...5605092b_1.jpg

koolaid6666,
to Change the 1997-2002 Chevrolet Express/GMC Savanna to the later style 2003-2012 Express/Savanna you will have to change out the radiator, core support, fan shroud, possibly the A/C condensor, both left/right fenders, hood, grill, composite headlights, turn signals, bumper support and bumper. If you can find this stuff used/cheap it may be worth the retrofit but if you van has high miles it may be a better idea to sell the one you have and purchase a new model van...............................

Zuren
 

Zuren,
What model Silverado did you light bar fit? I like the look that it added to your van! NICE........................

Zuren,
What model year Silverado was the light bar for? I like the way it made your van look! NICE.......

I'm going to look for one at the junk yard. My 02 Engine is getting pulled for a rebuilt one so all the front end parts are being pulled off anyway. That's why i was thinking off updating. I have a insulated freezer van so changing Vans Is a costly thing. But i like the updated look. I updated one off my ford van to a newer nose was pretty easy to do.

I just wanted to add to this a little. I just did this with my '06 and wanted to point out the only two "critical" spots are the ones with the x's in the above pic. These are where the bottom of the new lights mount. All the rest of the stuff you cut out is just for clearance, so that isn't critical. Just hope this helps the next guy.


Brew

Thank you for this, i am getting the chrome grill and im gonna do the same lights, did you have to buy a harness kit to plug the new lights in with? on the yellow x's did you cut those out square with the yellow lines or drill holes?

I believe I bought harnesses off ebay. Ones specifically to convert from the square sealed lights, to the composite ones with the bulb. I don't recall exactly what the lights are, but you should be able to looks those up on any site like Autozone. It is something like, "H8 to 9115 harness" or something like that.

You will need to cut the X's out square, pretty much just how the picture looks. It was mentioned that if you look close at the radiator supports (part you cut out) there is a faint outline of where you need to cut. Mine was not like this, there was no indication of where I needed to cut. With the new lights in my hand, it was pretty obvious what to cut though. Easiest way to cut them is probably a dremel type tool with a thin disk type of bit.

As I mentioned above, the bigger parts that need to be cut out are not critical. I cut roughly what the picture showed, then nibbled away what I needed for the light to work. All in all, it was pretty easy.

thank you I will, i found bumpers grill and lights i got to find the harness then ill start buying it all.

The boneyard was the easy route. The harness, 2 headlights, the chrome grille, turn signals and side markers all came off of one van. Like the other poster I used a dremel tool to cut my radiator support wall to accept the composite headlights. I was done in less than an hour after gather the parts.

Note: changing the harness is easy. You will need to follow it up to the fenders and undo a small bolt on each side to pull the old harness out. Unplug the old harness and snap the new one into place and replace the bolts to the fenders. Easy, just a heads up and I believe they were 8mm. Long time ago.

Additionally, before placing the new chrome grille into place I put two coats of clear coat on it. Plastic with faux chrome isn't a longevity combo. The clear coat was worth the time to spray and let dry. Before spraying I used Mothers Car Wash solution on it to remove all residual road grime.

When you are finished you'll have a renewed sense of Pride of Ownership. Nothing like real bling without going overboard. ;)

I sold my van 2 years ago to the first "looker". He never asked if everything was original as it was clean. :D

Do you have cruise control? No??? That's fairly easy too but you will have to change the turn signal lever on the steering column. It's all plug and play. Just a couple of bolts and mounts then connect to the throttle. Boneyard again! :)

While you're at the boneyard you may want to look for a 9 passenger van and take the rear speaker header and plugs. Self tapping screws attach the plastic header into place and the connection to the stereo is already in place. Clean look and the sound is fabulous in that cavern.

Drove that 2002 van for 2 years and was able to near double my money with the few changes.

!!!!!!! Starcraft leather seats are a must have!!! If you see them, get them. They will not be there when you decide that you want to go back and get them!

Good luck with your upgrades. (damn, forgot to mention chrome bumpers .. $75 each and they make the difference!)

It may have been mentioned before (at least in a different thread), but I just realized there are aftermarket Cadillac conversions for these vans.
http://www.2040cars.com/_content/car...464967/002.jpg

Funny, our vans must have been twins. I added the nicer front end too, added cruise (mine was definitely not plug and play), added speakers, added starcraft seats, etc

Really, it was no trouble at all. Bolted the mount to the firewall, servo to the mount, cable to the throttle and plugged in the servo. The turn signal was a paid change as I didn't want to mess with the air bag nor did I have the right tools to disassemble the column.

Cruise worked fine. What more did you have to do?

Insulation: I used some surplus carpet pad that I got from a flooring store. Took 2 rolls of double sided tape but I did the ceiling and walls. Quite a difference in road noise, especially during rain storms. ;)

my van did not have the wiring for the cruise installed. So I had to start from a blank slate. I installed a new multiswitch on the column, grabbed the servo from the junk yard, and also grabbed a complete wiring harness from the junk yard. So it took me a few hours at the junk yard and about 6 more to get it installed in my van.

I didn't insulate, but I did add the peel'n'stick stuff to a bunch of areas.

Worth every penny on a long drive. The Starcraft seats & Cruise were must have items. Finding the speaker header for the rear was a bonus and eventually considered must have.

Adding the carpet padding as insulation on the roof was pretty straight forward and after installed the noise level in the van was reduced drastically. The cardboard headliners (3 pieces) came in handy as I was able to add an additional layer after taping the first layer into place. The headliners were rigid enough that I probably could have added a third if I wanted. 2 layers was nice, especially driving in rain. Keeping the temp level steady helped cut down on fan noise ... you already know how that goes. ;)

Wonder why yours didn't come prewired? Should I be asking wonder why mine did?

from my research, if you have a plain Jane cargo van, then you don't have the wiring. If you have a passenger van, or a van that has power windows/locks already (but no cruise) then the wiring would be there. And on '07+ I believe they are drive by wire, and nothing is needed in any, besides the column switch.

Mine is a plain cargo van, so I am not concerned about the rear much, it is all tools. I have the safety divider right behind the front seats, so I insulated that to basically separate the cab from the back. That cuts down on a ton of noise from the back, makes my heater and a/c awesome, etc.

I did add a backup camera since mine is a cargo van with no windows behind the drivers/passenger's. I also installed Blaupunkt head unit with gps, dvd, etc. And 6x9 speaker boxes behind the front seats so I am ok there. If I lived closer to a u-pull junk yard, I would probably do a few more things, but the closest one is about an hour and a half away.

For me the biggest thing was cruise. Then probably the seats, then down the line.

Well im even later to the party, but i have a 96' Express conversion van (even older!). Is this conversion possible for a van the age of mine?

Absolutely. Get the chrome bumpers too. The sidelights and turn signals you want to grab when you see them.

You should be good up to 2002 for harvesting parts.

Bought harness at local auto parts store
 

We bought new harnesses at our local O'Reily auto parts store for $12

Thank you!
 

Thank you so much for posting this!! The picture was so helpful!!! Thank you

Hey guys since yall are talking headlights , new to site , I have a 88 chevy k1500 and was wondering what I have to do to swap from the quad headlights to the newer 98 style head lights would I have to get a new core support , I know I will have to do wiring .

Can you reverse this process?
 

We hit a deer with our 03 with composites. We can't find used parts anywhere, so we were thinking about going sealed beam conversion just to keep our van going . Is this process possible?

It should be possible without any problems, but I wouldn't myself unless you like the look of the sealed beam style front end. The parts new are pretty darn cheap if you go through a company like certifit. I converted mine to the composite style and I think it was only like $150 for everything.

Certifit Online

if you have one around, you can swing by and check out prices. They used to have a catalog with prices, but they don't any more. If I recall, the headlights were about $35 apiece with bulbs, and the whole grill was like $75 +/-

https://chevroletforum.com/forum/moz...r-marker-1.png
https://chevroletforum.com/forum/moz...r-marker-1.png

Rock Auto has the composites for an '03 for around $30.00 each.

Headlights cost $60 for a pair - ebay.com/itm/131869592286. Grill is around $160 on eBay or Amazon, all OEM quality stuff.
In addition, the sealed beam lights are much worse in doing their actual job - providing light..