Headlight Assembly

Remove and replace the headlight assembly on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including proper electrical disconnection and alignment adjustment.

Warnings

Tools required

Parts

• Headlight assembly (driver or passenger side) × 1 — Use OEM specification
• Headlight assembly gasket/seal (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Disconnect negative battery terminal and wait 2 minutes for electrical system discharge
4. Turn steering wheel to full opposite lock for easier access to headlight being replaced
5. Mark aim adjuster screw positions with masking tape for reference

Procedure

1. 1

   Access the headlight assembly
   Open the hood and secure it in the upright position. Identify the headlight assembly to be replaced. Note the location of the two vertical and one horizontal aim adjuster screws on the back of the assembly.
2. 2

   Disconnect electrical connectors
   Locate the main headlight electrical connector on the back of the assembly. Press the release tab and pull the connector straight back to disconnect. If equipped with daytime running light or turn signal integrated bulbs, disconnect those connectors as well by pressing their release tabs.
3. 3

   Remove grille or fascia screws if needed
   Depending on the specific trim level, you may need to remove 2-3 screws securing the upper grille or fascia panel that overlaps the headlight assembly. Use an 8mm socket to remove these fasteners. Keep track of all hardware.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
4. 4

   Remove headlight mounting bolts
   Locate the three headlight assembly mounting bolts - typically two on top and one on the outboard side. Use a 10mm socket to remove all three bolts. Support the headlight assembly with one hand as you remove the final bolt to prevent it from falling.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
5. 5

   Remove headlight assembly
   Carefully pull the headlight assembly straight forward away from the vehicle. The assembly may have alignment pins that need to clear their grommets. Tilt and maneuver as needed while being careful not to scratch the paint on surrounding panels. Place the old assembly on a clean work surface.
6. 6

   Inspect mounting points and clean
   Inspect the headlight mounting bracket and alignment pin grommets on the vehicle for damage, corrosion, or debris. Clean the mounting surface with a shop towel. Check the condition of any rubber seals or gaskets - replace if cracked or deteriorated.
7. 7

   Install new headlight assembly
   Position the new headlight assembly near the mounting location. Align the locating pins with their grommets and the mounting bolt holes. Carefully press the assembly into position, ensuring all alignment features are properly seated and the assembly sits flush against the mounting surface.
8. 8

   Install mounting bolts
   Thread all three headlight assembly mounting bolts by hand first to prevent cross-threading. Once all bolts are hand-tight, use a torque wrench and 10mm socket to tighten them in a crossing pattern to the specified torque of 10.0 Nm (7.0 lb-ft). Do not overtighten as this can crack the mounting tabs.
   Torque spec

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

   Reconnect electrical connectors
   Reconnect the main headlight electrical connector by aligning the connector and pressing firmly until you hear and feel a positive click. Verify the locking tab is fully engaged. Reconnect any additional connectors for integrated turn signals or running lights in the same manner.
10. 10

    Reinstall grille or fascia components
    If any grille or fascia screws were removed in step 3, reinstall them now. Torque these cover screws to 15.0 Nm (11.0 lb-ft) using a torque wrench and appropriate socket.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
11. 11

    Reconnect battery and test
    Reconnect the negative battery terminal. Turn the headlight switch to verify low beam, high beam, and turn signal functions all operate correctly. Check that daytime running lights function if equipped. Verify no warning lights appear on the instrument cluster.

Reassembly

1. Return steering wheel to center position before driving
2. Headlight aim should be checked and adjusted using the adjuster screws - use reference marks made during preparation
3. Professional headlight aim inspection is recommended to ensure proper beam pattern and compliance with regulations

Verification

• Operate headlights in low beam, high beam, and flash-to-pass modes to confirm all functions work properly
• Verify turn signals and daytime running lights function if integrated into the headlight assembly
• Inspect headlight assembly for proper seating and no gaps between assembly and body panels
• Check that all mounting bolts are properly torqued and secure
• Visually inspect beam pattern against a wall or garage door - both headlights should have similar height and cutoff patterns
• Have headlight aim professionally checked and adjusted within 100 miles of installation

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