I finally ordered new headlight assemblies for my 2007 Express 1500. Not only were the old ones oxidized, but they had tons of micro cracks in them. No buffing kit is going to fix that!

As for the headlight bulbs, I was really excited about ordering some super bright, white, LED bulbs. But I just don't think any of them would fit. The low beam bulbs are butted up right up against a plastic panel. And the LED's have heat sinks and fans on them. And I don't think I'm going to start cutting that plastic up to make room. Have any of you all upgraded your bulbs to LED in a Express van (with the plastic headlight assemblies)?

If LED's can't fit, I might buy some Sylvania Silverstar-Ultra halogens for my low beams, and I'll save my old ones as backups. I'll just keep my current high beam bulbs, I rarely use them anyway.

Update: I ordered some of these tonight. I found a guy on YouTube who installed these on his Chevy Express with no clearance issues:

I'll let you all know how they work out.

 

I have bad experience with Sylvania. Worst bulbs ever. GE & Philips are much, much better.

 

The new headlight bezels arrived today. They look nice but on one of them, the headlight beam adjustment screw is off at an angle, the other one not so bad. That might pose a problem when it comes time for adjustment. Is there a way to adjust that. It would be a shame to have to send them back because of that. I don't want to just try twisting it or I might break it.