Can you use 03-04 front grill with 01 style glass headlights?
#1
#2
#4
#5
Yes any 94-04 Grill can be swapped around but small mods are necessary.
I have an 02 D2 Kalahari with an 03-04 Grill, I installed a TF front winch bumper and with the original 99-02 grill it would have required me to cut off nearly 1inch off the bottom (original Saudi Grill) which I was not going to do! The 03-04 grill worked out perfectly as it isn't as tall (due to the 03-04 front bumper design). That allowed me to install a Warn Winch without chopping up the grill and it also meant I didn't have to cut it to install the TF front bumper. The only thing you need to do is shorten the front corner bezels (ones that sit under a 99-02 D2 headlight). I just used a hacksaw and it was super simple. Then I made 2 little metal brackets to support the front corner bezels.
My 99 D2 is also now sporting an 03-04 grill as the original fell to pieces and I did the same procedure as mentioned above. The 03-04 Grill is made out of a much more durable plastic vs 94-02 units that reminded me more of egg shells.
I have an 02 D2 Kalahari with an 03-04 Grill, I installed a TF front winch bumper and with the original 99-02 grill it would have required me to cut off nearly 1inch off the bottom (original Saudi Grill) which I was not going to do! The 03-04 grill worked out perfectly as it isn't as tall (due to the 03-04 front bumper design). That allowed me to install a Warn Winch without chopping up the grill and it also meant I didn't have to cut it to install the TF front bumper. The only thing you need to do is shorten the front corner bezels (ones that sit under a 99-02 D2 headlight). I just used a hacksaw and it was super simple. Then I made 2 little metal brackets to support the front corner bezels.
My 99 D2 is also now sporting an 03-04 grill as the original fell to pieces and I did the same procedure as mentioned above. The 03-04 Grill is made out of a much more durable plastic vs 94-02 units that reminded me more of egg shells.
Last edited by Best4x4; 04-04-2020 at 10:01 AM.
The following 2 users liked this post by Best4x4:
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#6
Yes any 94-04 Grill can be swapped around but small mods are necessary.
I have an 02 D2 Kalahari with an 03-04 Grill, I installed a TF front winch bumper and with the original 99-02 grill it would have required me to cut off nearly 1inch off the bottom (original Saudi Grill) which I was not going to do! The 03-04 grill worked out perfectly as it isn't as tall (due to the 03-04 front bumper design). That allowed me to install a Warn Winch without chopping up the grill and it also meant I didn't have to cut it to install the TF front bumper. The only thing you need to do is shorten the front corner bezels (ones that sit under a 99-02 D2 headlight). I just used a hacksaw and it was super simple. Then I made 2 little metal brackets to support the front corner bezels.
My 99 D2 is also now sporting an 03-04 grill as the original fell to pieces and I did the same procedure as mentioned above. The 03-04 Grill is made out of a much more durable plastic vs 94-02 units that reminded me more of egg shells.
I have an 02 D2 Kalahari with an 03-04 Grill, I installed a TF front winch bumper and with the original 99-02 grill it would have required me to cut off nearly 1inch off the bottom (original Saudi Grill) which I was not going to do! The 03-04 grill worked out perfectly as it isn't as tall (due to the 03-04 front bumper design). That allowed me to install a Warn Winch without chopping up the grill and it also meant I didn't have to cut it to install the TF front bumper. The only thing you need to do is shorten the front corner bezels (ones that sit under a 99-02 D2 headlight). I just used a hacksaw and it was super simple. Then I made 2 little metal brackets to support the front corner bezels.
My 99 D2 is also now sporting an 03-04 grill as the original fell to pieces and I did the same procedure as mentioned above. The 03-04 Grill is made out of a much more durable plastic vs 94-02 units that reminded me more of egg shells.
#7
#8
I used a pair of those sticky tape backed zip tie holders on the Kalahari. On the 99 I just drilled 2 holes & used 2 stainless steel bolts. The TF bumper sits directly under the bezel so it just needed to be held front to back. On the 99 with an ARB I needed to make sure it was good at fully supporting the bezel weight so I used a bolt. Looks fine IMHO.
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