Replace the LED headlight module assembly on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including removal of bumper cover components and headlight assembly.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification - Mopar part specific to 2014 Ram 2500
• Headlight Module Gasket/Seal (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all lights and accessories, then turn ignition to OFF position
3. Allow engine to cool completely if recently operated
4. Open hood and secure with prop rod
5. Disconnect negative battery terminal to prevent electrical shorts during module replacement
6. Wait 2 minutes after battery disconnect for capacitor discharge
7. Cover front fender with protective cloth to prevent scratches during work

Procedure

1. 1

   Remove grille assembly mounting fasteners
   Remove the upper grille mounting bolts using a 10mm socket. There are typically 4-6 bolts along the top edge of the grille. Then remove the Torx T20 screws securing the lower grille sections. Note the location of each fastener type as they differ.
2. 2

   Disconnect grille and access headlight area
   Carefully pull the grille assembly forward to release the retention clips along the bottom edge. Disconnect any ambient temperature sensor wiring if equipped. Set grille aside in a safe location. This provides necessary access to the headlight mounting points.
3. 3

   Remove headlight assembly retaining bolts
   Locate the three headlight assembly mounting bolts accessible from the engine bay. Remove the upper mounting bolt (13mm), mid-level mounting bolt (13mm), and lower mounting bolt (13mm). Support the headlight assembly with one hand while removing the final bolt to prevent it from falling.
   ⚠Headlight assembly is heavier than it appears due to LED module and housing. Support weight during removal to prevent dropping.
4. 4

   Disconnect headlight electrical connectors
   Reach behind the headlight assembly and locate the main electrical connector for the LED module. Press the release tab and pull the connector straight out. Also disconnect the smaller connector for the position/marker light if present. Note the routing of wiring harnesses for reassembly.
5. 5

   Remove headlight assembly from vehicle
   Carefully pull the headlight assembly forward and outward, guiding it past any mounting brackets or wiring. The assembly slides forward on locating pins. Tilt slightly if needed to clear the fender edge. Place assembly on clean, padded work surface with lens facing up.
6. 6

   Remove LED module cover screws
   With the headlight assembly on your work surface, locate the rear dust cover or access panel. Remove the screws (typically T25 Torx) securing the cover. Remove cover carefully to access the LED module mounting points. Inspect the seal for damage and replace if deteriorated.
   Torque spec

   Cover Screws15 Nm (11 lb-ft)
7. 7

   Disconnect LED module electrical connection
   Inside the headlight assembly, locate the LED module connector. This is a sealed connector at the back of the LED module. Press the release tab and disconnect carefully. Note the orientation of the connector and any locking mechanisms.
8. 8

   Remove LED module mounting hardware
   Locate and remove the LED module mounting bolts (typically 3-4 bolts) that secure the module to the headlight housing. Use caution as the module may be sealed with thermal compound or gasket material. Keep track of any spacers or washers used with the mounting bolts.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Extract old LED module
   Carefully pull the LED module assembly from the headlight housing. The module may have alignment pins or tabs that must be disengaged. If resistance is felt, check for any remaining fasteners or sealing material. Avoid prying against circuit boards or LED arrays.
   ⚠Do not force the LED module out. Excessive force can crack the housing or damage mounting points. Check for hidden clips or fasteners if module does not release easily.
10. 10

    Prepare housing and install new LED module
    Clean the LED module mounting surface in the headlight housing using a clean, lint-free cloth. Remove any old gasket material or debris. Ensure alignment pins in housing are undamaged. Position the new LED module, aligning it with mounting holes and any locating pins. Ensure any gasket or seal is properly seated.
11. 11

    Secure new LED module
    Install the LED module mounting bolts and tighten in a cross-pattern to ensure even seating. Torque to specification using a torque wrench. Verify the module sits flush against the housing with no gaps. Connect the LED module electrical connector firmly until the locking tab clicks into place.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Reinstall module cover
    Position the dust cover or access panel back onto the headlight assembly, ensuring the seal is properly aligned. Install and torque the cover screws to specification. Tighten in a cross-pattern to ensure even compression of the seal and prevent water intrusion.
    Torque spec

    Cover Screws15 Nm (11 lb-ft)
13. 13

    Reinstall headlight assembly to vehicle
    Position the headlight assembly in the mounting location, aligning the locating pins with their holes in the fender and core support. Carefully push the assembly rearward until it seats fully. Install the three mounting bolts hand-tight first to ensure proper alignment, then torque to specification starting with the upper bolt.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
14. 14

    Reconnect electrical connections
    Connect the main LED module electrical connector, pressing firmly until the locking tab engages with an audible click. Connect the position/marker light connector if equipped. Ensure no wiring is pinched between body panels or sharp edges. Route wiring as originally positioned.
15. 15

    Reinstall grille and reconnect battery
    Position the grille assembly back onto the vehicle, engaging the lower retention clips first. Reconnect any sensor wiring. Install all grille mounting fasteners, working from top to bottom. Reconnect the negative battery terminal and torque the battery terminal bolt to specification.
    ⚠Do not overtighten battery terminal bolts. Excessive torque can crack the terminal or damage the battery post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify headlight assembly is flush with surrounding body panels with no gaps
3. Check that all grille fasteners are tightened and no clips are broken
4. Confirm no tools or parts remain in engine compartment before closing hood

Verification

• Turn ignition to ON position without starting engine and verify no warning lights related to lighting system appear on instrument cluster
• Test low beam function - LED module should illuminate immediately with no flickering or delay
• Test high beam function - verify full brightness and proper beam pattern
• Test turn signal and parking light functions to ensure all circuits are operating
• Perform a visual inspection with lights on to verify proper beam pattern alignment - no excessive scatter or dark spots
• Check for any error codes using an OBD-II scanner to confirm no lighting system faults are present
• Test drive vehicle after dark to verify headlight output is adequate and beam pattern is correct for safe operation

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