HID Ballast

This procedure covers the removal and replacement of a failed HID (High Intensity Discharge) headlight ballast on a 2014 Ram 2500 with 6.7L Cummins diesel engine.

Warnings

Tools required

Parts

• HID Ballast (Left or Right as needed) × 1 — Use OEM specification - Mopar 68088247AA or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off headlights and allow HID system to cool for at least 5 minutes
3. Open hood and secure with prop rod
4. Identify which ballast requires replacement (driver or passenger side)

Procedure

1. 1

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

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Access headlight assembly area
   Locate the headlight assembly on the affected side. On the 2014 Ram 2500, the HID ballast is mounted behind the headlight assembly. You may need to remove the air intake duct on the driver side for better access. Simply loosen the clamps and move aside without fully removing.
3. 3

   Locate HID ballast
   The HID ballast is a rectangular metal or plastic box mounted to the back of the headlight housing or nearby mounting bracket. Identify the ballast by tracing the wire harness from the back of the HID bulb. The ballast will have a power input connector and an output cable going to the HID bulb.
4. 4

   Disconnect ballast electrical connectors
   Disconnect the main power connector from the ballast by pressing the release tab and pulling straight out. Then disconnect the high-voltage output connector that runs to the HID bulb by pressing its locking tab and carefully separating. Do not pull on wires; always pull on connector bodies.
5. 5

   Remove ballast mounting bolts
   Using an 8mm socket, remove the mounting bolts securing the ballast to its bracket. Most Ram 2500 ballasts use two or three mounting bolts. Keep track of any spacers or washers.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
6. 6

   Remove old ballast
   Carefully remove the ballast from its mounting location. You may need to rotate or angle it to clear surrounding components. Inspect the mounting bracket for corrosion or damage and clean if necessary.
7. 7

   Prepare new ballast
   Unpack the new HID ballast and verify it matches the original part. Check that all connectors are clean and free of debris. If applicable, transfer any mounting brackets from the old ballast to the new one if they are not pre-installed.
8. 8

   Install new ballast
   Position the new ballast into the mounting location, ensuring proper orientation with connectors facing the correct direction for easy connection. Align the mounting holes with the bracket.
9. 9

   Torque ballast mounting bolts
   Install the mounting bolts and tighten to specification using a torque wrench. Ensure the ballast is secure and properly seated against its mounting surface.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Reconnect electrical connectors
    Connect the high-voltage output connector to the HID bulb first, ensuring it clicks into place securely. Then connect the main power input connector to the ballast, verifying a positive lock. Apply a small amount of dielectric grease to connectors if desired for corrosion protection.
11. 11

    Reinstall air intake if removed
    If the air intake duct was moved or removed for access, reposition it properly and secure all clamps. Ensure no hoses are kinked or disconnected.
12. 12

    Reconnect battery
    Reconnect the negative battery terminal and torque the terminal bolt to specification. Ensure clean contact between terminal and post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure no tools or parts were left in engine bay
3. Confirm air intake system is properly reinstalled if disturbed

Verification

• Turn ignition to ON position and activate headlights to verify HID bulb fires and reaches full brightness within 10-15 seconds
• Check for proper low and high beam operation on the repaired side
• Verify no error messages or warning lights appear on instrument cluster
• Visually inspect the repair area to ensure no loose wires or improperly seated connectors
• Allow system to run for 2-3 minutes and verify ballast does not overheat or produce burning smell
• Test headlight aim if necessary and adjust per manufacturer specifications

More procedures for this vehicle