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  #1  
Old 03-31-2018
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Gatorgrl Gatorgrl is offline
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Default FC Ballast removal pictorial

Here's my pictorial on how we removed our old fluorescent ballasts so we could upgrade them all to LED. Hope it helps.


The special tools needed to get to those hidden fluorescents:



Gotta love those special tools. Here's the ratcheting screwdriver in action with room to spare!



And in less than 5 minutes, the light is free, no ladders or band-aides needed.




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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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  #2  
Old 03-31-2018
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Default Tackling the ballast

Now let's tackle those pesky ballasts.


Here's the tools I used for this part of the project:



Start by cutting the ballast wires.



And this is how it looks afterward:
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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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  #3  
Old 03-31-2018
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Now remove the end plate. Unscrew the one screw and then hammer out the rivets.



Use a sharp chisel to loosen the rivet and a part of side cutter to pull it out.




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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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  #4  
Old 03-31-2018
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Now remove the tiny screw holding the aluminum cover to the ballast.



And then pry it off gently because you may want to reuse this to cover the hole left from removing the ballast.


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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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  #5  
Old 03-31-2018
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Gatorgrl Gatorgrl is offline
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Now we have to remove the ballast ground that is secured with a tiny screw through the fluorescent light holder and has a blind nut on the back of it, so make sure you hold that too.



Then push the ballast wires back through their hole to remove the ballast:



Gently lift up on the ballast and remove, careful not to damage or bend the light fixture.



And you're home free!
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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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  #6  
Old 03-31-2018
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We decided to go with LED tape in these lights so the old fluorescent holders were also removed. No holes needed to be drilled because we just used the holes left by removing the white plastic light holders.
Hope this little tutorial helps anyone else with a FC that wants to upgrade their rig to LED.
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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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  #7  
Old 03-31-2018
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Randy Dupree Randy Dupree is offline
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Nice job!!
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Randy Dupree
2000 LXI 43
Bainbridge,Ga.
Port St Joe Fl.
www.buybyebluebird.com

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  #8  
Old 03-31-2018
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Great job. The pictures really help!
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95 WB42 S-60
88 WB40 2010/14
Brooks, GA
Kip Cindy & Cody
678-523-7920
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  #9  
Old 03-31-2018
CaptPegLeg CaptPegLeg is offline
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Looks like your ballast came out east but if its stuck good a heat gun softens the adhesive. Also, as someone else mentioned be sure to use a grommet or something to protect the wire from the fixture.
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Bob Sumners
1993 WB
1983 PT35 Sold
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  #10  
Old 03-31-2018
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Thanks for the stamp of approval.
also thanks for the tip on shielding the wires.
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Dana (The Wanderer, Builder, Restorer)
Tony (The Grumpy Mechanic)

Lee County, Florida

1983 FC35 3208T "Gen X Express"
1991 Toyota 4Runner TOAD or
1980 Camaro TOAD

danahcks@aol.com
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