Headlight Assembly

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

Warnings

Tools required

Parts

• Headlight assembly (specify driver or passenger side) × 1 — Use OEM specification or DOT-approved replacement

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off headlights and allow bulbs to cool for at least 10 minutes if recently used
3. Open hood and secure with prop rod

Procedure

1. 1

   Access headlight assembly mounting points
   Locate the headlight assembly from the front of the vehicle. Identify the mounting bolts/screws accessible from the top of the assembly near the grille area (typically two to four fasteners depending on model year and generation). On some model years, a plastic radiator cover may partially obstruct access and should be moved aside if present.
2. 2

   Disconnect headlight electrical connector
   Reach behind the headlight assembly and locate the main electrical connector. Press the release tab and pull the connector straight back to disconnect. If corrosion is present, carefully wiggle while pulling to avoid breaking the connector tabs.
3. 3

   Remove headlight assembly mounting bolts
   Using the appropriate socket or Phillips screwdriver (verify fastener type for your model year), remove the upper mounting fasteners securing the headlight assembly to the radiator support bracket. Keep these bolts organized as they will be reused during installation.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
4. 4

   Release lower mounting tab
   The headlight assembly has a lower locating tab/pin that slots into the radiator support or header panel. Gently pull the top of the assembly forward while guiding the bottom tab out of its slot. The assembly may require slight upward movement while pulling forward to clear the mounting point.
5. 5

   Remove headlight assembly
   Once the lower tab is clear, carefully pull the headlight assembly forward and away from the vehicle. Inspect the mounting points on the vehicle for damage or corrosion. Clean mounting surfaces if rust or debris is present.
6. 6

   Prepare new headlight assembly
   Remove the new headlight assembly from packaging and inspect for shipping damage. Verify that all mounting tabs and adjustment screws are intact. If bulbs are not pre-installed, install appropriate bulbs according to the manufacturer's instructions before installation.
7. 7

   Install new headlight assembly
   Position the new headlight assembly near the mounting location. First, align and insert the lower mounting tab into the slot in the bumper support. Once engaged, pivot the assembly back toward the radiator support while guiding the upper mounting holes into alignment.
8. 8

   Install and torque mounting bolts
   Thread the two upper mounting bolts by hand to avoid cross-threading. Once both fasteners are started, tighten them snug by hand until the assembly is seated firmly against the mounting points. Do not overtighten, as excessive torque can crack the plastic housing.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
9. 9

   Reconnect electrical connector
   Reach behind the headlight assembly and plug the electrical connector into the back of the headlight housing. Ensure the connector locks into place with an audible click. Gently tug on the connector to verify it is fully seated.
10. 10

    Perform initial headlight aim check
    Turn on the headlights and verify both low and high beams function correctly. Observe the beam pattern on a wall or garage door approximately 25 feet away. The headlight aim adjustment screw(s) are accessible near the top of the assembly if preliminary adjustment is needed (adjuster location and count vary by model year).
    Torque spec

    Adjuster Screws3 Nm (2 lb-ft)

Reassembly

1. Ensure all electrical connections are secure and moisture-free
2. Verify headlight assembly is firmly seated with no gaps between assembly and mounting surfaces
3. Reinstall any radiator covers or trim pieces that were moved during access

Verification

• Test low beam, high beam, and turn signal functions on the replaced assembly
• Verify headlight assembly is securely mounted with no movement when pressed
• Check headlight aim adjustment and adjust if beam pattern is significantly misaligned with opposite side
• Inspect for proper sealing around the headlight assembly to prevent moisture intrusion

Related trouble codes on this vehicle

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