Fog Light Assembly

This procedure covers removal and replacement of the fog light assembly on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Fog light assembly (driver or passenger side) × 1 — Use OEM specification or aftermarket equivalent
• Fog light bulb (if not included with assembly) × 1 — H3 12V 55W bulb typical

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn fog lights and all electrical accessories off
3. Turn ignition to OFF position and remove key
4. Allow fog light bulbs to cool for at least 15 minutes if recently used
5. Verify which side requires fog light replacement

Procedure

1. 1

   Access fog light assembly from below
   Position yourself under the front bumper on the side requiring service. You may need to turn the front wheels fully to the opposite side for better access. The fog light assembly is mounted below the bumper, typically in or near the lower valance panel. Verify bulb type against vehicle-specific spec (commonly 899 or 9145/H10 on this platform).
2. 2

   Disconnect electrical connector
   Locate the wiring harness connector at the back of the fog light assembly. Press the release tab on the connector and pull straight back to disconnect. If the connector is difficult to reach, you may need to remove it after loosening the mounting hardware in the next step.
3. 3

   Remove fog light mounting hardware
   Locate the mounting bolts or screws securing the fog light assembly to the bracket or bumper. Most assemblies use either two or three mounting points. Remove the fasteners completely. Keep track of any washers or spacers used with the mounting hardware.
4. 4

   Remove fog light assembly
   Carefully pull the fog light assembly forward and out of the mounting bracket. If you were unable to disconnect the electrical connector earlier, disconnect it now. Remove the assembly from the vehicle and inspect the mounting bracket for damage or corrosion.
5. 5

   Prepare new fog light assembly
   If the replacement fog light assembly does not include a bulb, transfer the bulb from the old assembly or install a new bulb. Handle bulbs by the base only, avoiding contact with the glass envelope. Ensure any gaskets or seals are properly positioned on the new assembly.
6. 6

   Install new fog light assembly
   Position the new fog light assembly into the mounting bracket, ensuring proper alignment. If necessary, connect the electrical connector first if access will be limited once mounted. Insert and hand-thread all mounting fasteners before fully tightening.
7. 7

   Torque mounting fasteners
   Tighten the fog light mounting fasteners evenly in a cross pattern if multiple fasteners are used. Tighten the small mounting fasteners snugly by hand. These fog light fasteners are not published with a torque specification; do not overtighten screws threaded into plastic to avoid stripping.
8. 8

   Connect electrical connector
   If not already connected, firmly push the electrical connector onto the fog light assembly terminals until it clicks into place. Ensure the connector is fully seated and the locking tab is engaged. Tuck any excess wiring back into the routing channels to prevent interference with moving components.

Reassembly

1. Ensure fog light assembly is securely mounted with no excessive movement or play
2. Verify electrical connector is fully seated and locked
3. Check that wiring harness is properly routed and secured away from heat sources and moving parts

Verification

• Turn ignition to ON position without starting engine
• Activate fog lights using the dashboard control switch
• Verify the newly installed fog light illuminates with proper brightness and beam pattern
• Check that both fog lights illuminate if both are installed
• Inspect for any light leaks around the fog light housing seal
• Turn fog lights off and verify they turn off completely
• Perform a visual inspection from the front of the vehicle to ensure fog light is properly aimed and aligned with the opposite side

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