This procedure covers the replacement of a failed HID (High Intensity Discharge) headlight ballast on a 2012-2018 Jeep Wrangler JK with the 3.6L V6 engine.

Warnings

Tools required

Parts

• HID ballast × 1 — Use OEM specification - Mopar 68089195AB or equivalent
• Dielectric grease × 1 — Small packet for connector protection

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn off headlights and allow to cool for at least 15 minutes if recently operated
3. Open hood and secure with prop rod
4. Identify which ballast has failed (driver or passenger side) by observing which headlight does not illuminate or flickers
5. Disconnect negative battery terminal and wait 2 minutes for capacitor discharge

Procedure

1. 1

   Disconnect negative battery terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the negative cable from the battery post and secure it away from the battery to prevent accidental reconnection during the repair.
   Torque spec

   Battery Terminal Bolts8 Nm (6 lb-ft)
2. 2

   Access the headlight area
   For 2012-2014 models, remove the plastic push-pin fasteners securing the inner fender liner near the headlight. Peel back the liner to expose the ballast mounted on the inner fender well. For 2015-2018 models, you may need to remove the entire headlight assembly by removing the four headlight mounting bolts to access the ballast behind the assembly.
3. 3

   Locate the HID ballast
   The ballast is a rectangular metal or plastic box approximately 4x3x1 inches with three electrical connectors: one power input connector, one HID bulb output connector, and one ground wire. Note the orientation and routing of all wiring before disconnection.
4. 4

   Disconnect ballast electrical connectors
   Press the locking tab on the main power input connector and pull straight away from the ballast. Disconnect the HID bulb output connector by pressing the release tab and pulling firmly. The connector may be tight due to weatherproofing seals.
   ⚠Do not pull on wires themselves. Always grip the connector body to avoid damaging the wiring harness.
5. 5

   Remove ground connection
   Using a 10mm socket, remove the ground bolt securing the ballast ground wire to the body or fender. Keep the bolt and ground wire attached to the old ballast for reference during installation.
   Torque spec

   Ground Bolt16 Nm (12 lb-ft)
6. 6

   Remove ballast mounting bolts
   Remove the two or three bolts securing the ballast to its mounting bracket. The bolts are typically 10mm. Carefully extract the ballast from its mounting location, taking care not to drop it as it may still contain residual charge.
   Torque spec

   Bracket Bolts23 Nm (17 lb-ft)
7. 7

   Compare old and new ballast
   Verify the new ballast matches the old unit in terms of connector types, mounting hole locations, and part number. Confirm the voltage rating matches (typically 35W or 55W). Transfer the mounting bracket to the new ballast if it was removed with the old unit.
8. 8

   Install new ballast
   Position the new ballast in the mounting location with the same orientation as the old unit. Thread the mounting bolts by hand first to ensure proper alignment, then tighten to specification using a torque wrench.
   Torque spec

   Bracket Bolts23 Nm (17 lb-ft)
9. 9

   Connect ground wire
   Ensure the ground connection point on the body or fender is clean and free of paint, rust, or corrosion. Use a wire brush or sandpaper if necessary. Attach the ground wire to the grounding point and tighten the ground bolt to specification.
   Torque spec

   Ground Bolt16 Nm (12 lb-ft)
10. 10

    Reconnect electrical connectors
    Apply a small amount of dielectric grease to the terminals of both the power input connector and HID bulb output connector. Connect both plugs to the new ballast, ensuring you hear and feel a positive click indicating the locking tabs have engaged properly.
11. 11

    Reinstall access components
    For 2012-2014 models, reposition the inner fender liner and secure with the original push-pin fasteners. For 2015-2018 models, if the headlight assembly was removed, reinstall it and torque the mounting bolts to specification. Ensure all wiring is properly routed and not pinched.
    Torque spec

    Mounting Bolts39 Nm (29 lb-ft)
12. 12

    Reconnect battery
    Reconnect the negative battery terminal to the battery post. Clean both the terminal and post if corrosion is present. Tighten the terminal bolt to specification using a torque wrench.
    Torque spec

    Battery Terminal Bolts8 Nm (6 lb-ft)

Reassembly

1. Double-check that all electrical connectors are fully seated and locked
2. Verify no tools or parts were left in the engine compartment
3. Ensure all fender liner fasteners are properly secured to prevent wind noise or water intrusion
4. Route all wiring away from hot engine components and moving parts

Verification

• Turn the ignition to the ON position without starting the engine
• Turn on the headlights and verify the repaired HID bulb illuminates properly within 3-5 seconds (normal HID warm-up time)
• Check that the light color matches the opposite side and remains steady without flickering
• Cycle the headlights off and on 2-3 times to confirm consistent operation
• Verify no warning lights appear on the instrument cluster
• Inspect the repair area for any loose wiring or improperly secured components
• Test drive the vehicle and confirm headlights function properly over bumps and during turns

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