electrical

LED Headlight Module

for 1994–2007 Dodge Ram 2500 5.9L I6 Cummins Diesel · 4WD

Difficulty

Easy

Time

1.2 h

Tools

Steps

🔧Does this apply to your car? On many late-model vehicles (especially European makes) a replacement LED headlight module must be coded to the vehicle. Aftermarket-tool support varies by make — check before buying the part.

✓Fact-checked. Built from OLP's spec database, then independently fact-checked line by line with every correction applied. Master-tech sign-off by Chris Hackleman is queued. Cross-check torque values against the factory manual, and stop if anything looks unsafe. How our data is made.

This procedure covers the installation of aftermarket LED headlight modules to replace the factory halogen sealed beam headlights on 1994-2007 Dodge Ram 2500 trucks with the 5.9L Cummins diesel engine.

Warnings

⚠Always disconnect the negative battery terminal before working on electrical systems to prevent short circuits and module damage

ℹ️LED headlight modules may require load resistors or CANBUS adapters on some vehicles to prevent flicker or error codes, though typically not required on this model year range

⚠Verify LED module polarity and proper ground connection before final installation to prevent reverse polarity damage

ℹ️Some LED modules require specific aiming procedures different from factory sealed beam units; consult module instructions

Tools required

10mm socket and ratchetEssential

8mm socketEssential

Torque wrench (0-30 Nm range)Essential

Wire crimpers and heat shrink tubing

Dielectric grease

Electrical tapeEssential

Wire brush or sandpaperEssential

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Parts

LED headlight module (driver side) × 1 — 7-inch round LED module with H4 or H13 adapter
LED headlight module (passenger side) × 1 — 7-inch round LED module with H4 or H13 adapter
H4 to H13 adapter harness (if required) × 2 — Depends on LED module connector type
Headlight mounting ring/retainer × 2 — Use OEM specification or included with LED module

As an Amazon Associate and Autel/ANCEL partner, OLP earns from qualifying purchases — how we link. This never changes the specs we publish.

Preparation

Park vehicle on level surface and apply parking brake
Allow engine to cool completely if recently operated
Open hood and secure with prop rod
Gather all tools and new LED headlight modules with included hardware
Verify LED modules are correct 7-inch round size for 1994-2007 Ram 2500 applications

Procedure

1
Disconnect battery negative terminal
Using a 10mm socket, loosen the negative battery terminal bolt. Remove the negative cable from the battery terminal and position it away from the battery post to prevent accidental contact during the repair.
Torque spec
Battery Terminal Bolts6 Nm (4 lb-ft)
2
Remove driver side headlight bezel
Remove the grille or bezel retaining fasteners as required to access the headlight assembly (fastener count and type vary by year; verify on the actual vehicle). Carefully pull the bezel/grille away from the front fascia and set aside.
3
Remove driver side factory sealed beam unit
Remove the composite headlight housing mounting fasteners (typically 2-4 bolts/screws depending on year) securing the assembly to the core support. Once removed, twist the bulb retaining ring at the rear of the housing counterclockwise to release the bulb. Pull the composite headlight assembly forward and disconnect the factory 9004 (HB1) bulb connector from the back of the headlight assembly. Remove the factory unit completely.
⚠Do not adjust or remove the headlight aim adjustment screws during this procedure or you will need to re-aim headlights
4
Prepare ground connection for driver side
Locate the factory ground connection point on the headlight mounting bucket or nearby chassis. Using a wire brush or sandpaper, clean the ground contact surface on both the mounting point and the ground terminal of the LED module (if equipped with separate ground wire). Remove any paint, rust, or corrosion to ensure a clean metal-to-metal contact for proper LED function.
5
Connect driver side LED module wiring
If your LED bulb uses a different connector than the factory 9004 (HB1, 1994-2002) or 9007 (HB5, 2003-2007) harness, install the appropriate adapter harness between the factory connector and the LED bulb. Ensure the connector is fully seated with an audible click. If the LED module has a separate ground wire, connect it to the factory ground point on the headlight bucket. Apply dielectric grease to all electrical connections to prevent corrosion.
ℹ️Verify polarity markings on adapter harness match LED module requirements before connecting
Torque spec
Ground Strap Bolts12 Nm (9 lb-ft)
6
Install driver side LED module
Insert the LED bulb into the rear of the composite headlight housing and twist the retaining ring clockwise to lock it in place. Reinstall the composite housing into the core support and secure with the mounting fasteners. Install the retaining ring screws and tighten securely, but do not overtighten. Ensure the LED module is seated properly and the lens is flush with the mounting ring.
Torque spec
Module Mounting Bolts8 Nm (6 lb-ft)
7
Reinstall driver side headlight bezel
Position the headlight bezel back over the headlight assembly, aligning the mounting holes. Install all four bezel mounting screws and tighten to secure the bezel. Ensure the bezel is flush against the front fascia with no gaps.
8
Remove passenger side headlight bezel
Repeat the bezel removal process for the passenger side. Remove the four mounting screws securing the chrome or black headlight bezel trim ring and carefully remove the bezel from the front fascia.
9
Remove passenger side factory sealed beam unit
Remove the passenger side retaining ring screws (avoid the aim adjustment screws), remove the retaining ring, pull the sealed beam forward, and disconnect the factory connector from the back of the sealed beam unit. Remove the factory sealed beam completely.
10
Prepare ground connection for passenger side
Clean the ground contact surface on the passenger side headlight mounting bucket and the LED module ground terminal using a wire brush or sandpaper. Ensure all paint, rust, and corrosion are removed for a proper electrical connection.
11
Connect passenger side LED module wiring
Connect the adapter harness (if required) and factory connector to the passenger side LED module. Connect the ground wire to the factory ground point if applicable. Apply dielectric grease to all connections. Ensure all connections are secure and properly seated.
Torque spec
Ground Strap Bolts12 Nm (9 lb-ft)
12
Install passenger side LED module
Position the passenger side LED module into the headlight bucket with proper alignment. Install the retaining ring and retaining ring screws, ensuring the LED module is properly seated and flush with the mounting ring.
Torque spec
Module Mounting Bolts8 Nm (6 lb-ft)
13
Reinstall passenger side headlight bezel
Position the passenger side bezel over the headlight assembly and install all four mounting screws. Tighten securely and verify the bezel is flush against the fascia.
14
Reconnect battery and test operation
Reconnect the negative battery cable to the battery terminal. Using a torque wrench, tighten the battery terminal bolt to specification. Turn the ignition to the ON position (do not start engine) and test both low beam and high beam operation on both headlights. Verify proper LED illumination, correct polarity (proper beam pattern), and no flickering.
⚠Do not overtighten battery terminal bolts as this can damage the battery terminal or bolt threads
Torque spec
Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

Verify all bezel screws are properly tightened and bezels are flush
Ensure no wiring is pinched or exposed that could contact moving parts or hot engine components
Check that all electrical connections are secure and protected from moisture
Confirm both headlight modules are properly seated in mounting buckets

Verification

With engine off and ignition in ON position, test low beam operation on both headlights
Test high beam operation on both headlights and verify proper switching
Verify LED beam pattern is correct with a cutoff line on low beam and no scatter or dark spots
Check that no warning lights are illuminated on the instrument cluster
Test turn signals and parking lights to ensure no interference with LED headlight operation
Perform a night test drive to verify proper illumination and beam pattern on the road
Adjust headlight aim if necessary using the factory aim adjustment screws to ensure proper beam alignment (approximately 2 inches below horizontal at 25 feet)