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  • Electric Headlight Conversion Kit - THUNDERBIRD - Rebuilt ~ 1967 - 1969 Thunderbird - 20687
  • Electric Headlight Conversion Kit - THUNDERBIRD - Rebuilt ~ 1967 - 1969 Thunderbird - 20687
  • Electric Headlight Conversion Kit - THUNDERBIRD - Rebuilt ~ 1967 - 1969 Thunderbird - 20687

Item #: 20687

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Price: $746.25
    Cost: 59700
    Earns: 2985
    Bonus: 0


    Out of Stock, Discontinued - Unknown



    Due to overwhelming demand, WCCC is now able to offer a 1967 - 1969 Thunderbird Electric Headlight Door conversion kit. This kit will replace the old, tired, vacuum system that likes to leak and wear out.

    This kit consists of driver and passenger side electric actuator assemblies (remanufactured 1989 - 1992 Ford Probe motors) with a fused wiring loom and relay for easy installation. Includes detailed instructions. Simply remove all existing vacuum components and replace with this kit to have headlight covers that work under any conditions with the car running or not.

    NOTE: We also have a kit with good used electric motors as a cost-saving option.

    If you have a high performance engine with low vacuum, this is a must have kit for your Cougar.

    Actuator Heim joints are fully adjustable to keep your grille and headlight lids nice and straight without slack. Another advantage of this electric system is that it doesn't put constant pressure on your grille like the original vacuum system does.

    These kits have a 3 year full warranty against manufacturer defects.

    We've had questions about what body plug to use at the firewall when getting rid of the vacuum hoses and converting to the electric headlights. You can click on the link in the video, or get the 1 1/4" body plug here.

    We currently do not have a video for installing this kit on the Thunderbird, but aside from a few obvious differences, this video gives the basics on installation:

    Shipping Weight: 15.00 LBS
    (weight shown may be the dimensional weight)

    This item must ship via

    Printable PDF instructions:

    Electric Actuator Installation Instructions.

    Printable PDF Troubleshooting Help Guide:

    Electric Actuator Installation Troubleshooting Guide.

    Installation video:

    Note: video is for installation on a '67 or '68 Cougar

    Installation instructions:

    1. Unplug headlights

    2. Remove clips on vacuum motor arms to headlight doors.

    3. Remove 2 springs on each headlight door (4 total)

    4. Remove 4 bolts holding the center grill panel to the hood latch support.

    5. Remove 4 bolts holding right and left grill sections to hood latch support.

    6. Remove 2 nuts on back of each grill, located on bottom middle and end of grill (4 nuts


    7. Remove bolt on top of grill under the fender extension pass driver (2 bolts)

    8. Cover bumper, stone guard, carefully remove bolt on top of center of grill, holding on

    to grill, (may require 2 people) do this for passenger and driver sides.

    9. Unplug vacuum hoses from motors, remove 2 nuts holding each vacuum motor (4 nuts,

    bolts total) Remove motors.

    10. Disconnect vacuum hose at intake manifold and install a plug.

    Optional- Remove all vacuum hoses and vacuum reservoir under driver fender.

    11. Motor arms should be lined up in the area painted gray on the motor mount and

    motor arm. DO NOT connect any wires to power at this point, the motor could

    rotate automatically.

    12. Mount electric motor with mount on driver side, using original holes for vacuum

    motor. Push motor completely to rear then tighten nuts.

    13. Mount pass motor mount in original vacuum motor holes, mark 3rd hold and drill a

    5/16 hole, tighten nuts.

    14. Run wire harness to each motor, relay could be mounted on drivers or pass

    fenderwell. DO NOT connect any wires to power yet.

    15. Reinstall grills in reverse order, adjust headlight cover bumpers all the way in, do not

    reuse springs, they are no longer needed.

    16. Ensure the headlight covers are aligned, with the covers closed, check the gray mark

    on the motor arm and the motor mount and align them by rotating the motor knob, THIS

    IS CRITICAL, it is the start, closed position. Measure cover arms, shorten them as

    needed, attach the cover arms with bolts provided, bolts should point toward the center

    of car, tightening them will reduce slack and provide a better adjustment, you may have

    to do this step a few times for adjustment.

    17. Make sure the motors ARE NOT connected to power, then, by hand, rotate the knob

    counter clockwise to open the cover, continue turning counterclockwise

    Do this for both sides. Check for binding. Make adjustments to headlight cover arms as

    needed. Adjust cover arms, motor mount, grill, headlight cover bumper stops can be

    adjusted to ¼ inch from hitting the stops, but not needed …BEFORE POWER IS

    CONNECTED. When covers are closed, the motor arm and mark on motor mount

    should be aligned, failure to align them could burn motors, blow a fuse or damage

    your grill.




    COMPLETELY, check for alignment of gray start position.

    18. Connect wires, red wire to constant positive ie; battery positive or starter solenoid

    positive terminal. Black wire to a good ground.

    19. Simple test. Once the hot wire and ground are connected, you can test the opening

    and closing of the covers by touching the blue(or yellow) signal wire to the positive side

    of your battery. Holding the wire on the positive will open the covers, taking the wire off

    the positive will close them. (IF COMFORTABLE DOING THIS) KEEP HANDS



    20. Connect the signal wire, blue ( or yellow) wire to headlight dimmer switch wire… red

    w/ yellow stripe, wire should come from headlight switch,(67 Cougars with external

    vacuum switch may have a signal wire in engine bay located under windshield washer

    bag red w/ yellow stripe,check this wire for power with headlights on, no power when

    headlights are off ., or use dimmer switch)

    21. Turn the headlights on, covers should open. Ensure they are completely open. If

    they are too tight, the headlight cover arms may need to be adjusted, if they are too tight

    when open, lengthen the cover arm…shorten the cover arm if they are not open fully.

    Some headlight cover sag can be fixed by shortening the arms. Make

    adjustments to motor arms with power wire disconnected!!!

    Motors can rotate automatically and smash your hand!! Use

    headlight cover arms and stops to adjust covers. Motor arms can moved slightly for

    more adjustment but usually not needed.


    These items are considered race only, or off-road. Improper installation or any type of headlight, headlight door failure can cause serious injury or death. Car owner assumes all risk of failure of any kind upon installing these headlight door parts.

    Catheadlights( Joshua Duitman) is not responsible for any consequences should a failure of any kind occur.

    These parts must be installed by someone who is competent in installing and modifying automobile headlight systems.

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