Headlight Assembly

This procedure covers removal and replacement of the headlight assembly on a 2007 Ram 3500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Headlight assembly × 1 — Use OEM specification - specify left or right side
• Headlight bulbs if not included with assembly × 1 — Verify bulb type for your trim level

Preparation

1. Park vehicle on level surface and turn off ignition
2. Allow headlights to cool if recently used
3. Open and prop hood securely
4. Optionally mark headlight vertical and horizontal aim position on wall or with tape for reference

Procedure

1. 1

   Disconnect headlight electrical connector
   Reach behind the headlight assembly and locate the main electrical connector. Press the release tab and pull the connector straight back to disconnect it from the headlight assembly. If multiple connectors are present for different bulbs, disconnect all of them.
2. 2

   Remove upper mounting bolts
   Locate the two mounting fasteners along the top edge of the headlight assembly (verify head size — commonly 8mm or 10mm on this platform). These fasteners secure the headlight to the radiator support. Remove both bolts completely and set aside.
3. 3

   Remove side mounting bolt
   Check for any additional side or outboard mounting fastener near the fender (verify against service manual — not all trims have one). If present, remove this fastener; note its head size before removal. Remove this bolt completely.
4. 4

   Release lower retaining tabs
   The headlight assembly has plastic retaining tabs/locating pins that engage slots in the grille surround and core support bracket. Gently pull the top of the headlight assembly forward while applying slight downward pressure, then tilt the assembly up and out to disengage the lower tabs. Gently pull the top of the headlight assembly forward while applying slight downward pressure, then tilt the assembly up and out to disengage the lower tabs.
5. 5

   Remove headlight assembly
   Once the lower tabs are disengaged, carefully pull the headlight assembly straight forward and away from the vehicle. Be careful not to scratch the paint on the fender or bumper. Verify all electrical connectors are disconnected.
6. 6

   Transfer bulbs if necessary
   If your replacement headlight assembly does not include bulbs, remove the bulbs from the old assembly by rotating the bulb sockets counterclockwise and pulling them out. Install them into the new assembly by inserting and rotating clockwise until locked. Handle bulbs by the base only to avoid contaminating the glass with skin oils.
7. 7

   Install new headlight assembly
   Position the new headlight assembly near the mounting location. Align the lower retaining tabs with their slots in the bumper cover, then tilt the assembly down and push rearward until the tabs engage. Ensure the assembly is fully seated against the radiator support and fender.
8. 8

   Install mounting bolts
   Install the side mounting bolt first to hold the assembly in position, then install the two upper mounting bolts. Tighten all mounting fasteners snugly by hand (verify count and head size against the service manual), ensuring the headlight assembly is properly aligned with the surrounding body panels before final tightening. Do not overtighten as this can crack the plastic mounting ears.
9. 9

   Reconnect electrical connector
   Reconnect the headlight electrical connector by pushing it firmly onto the back of the headlight assembly until you hear or feel it click into place. Verify the connection is secure by gently tugging on the connector.
10. 10

    Test headlight operation
    Turn the ignition to the ON position without starting the engine. Test low beam, high beam, and turn signal functions to verify proper operation of the new headlight assembly. Check for any error messages on the instrument cluster.

Reassembly

1. Verify all three mounting bolts are snug but not overtightened
2. Confirm headlight assembly is flush with surrounding body panels
3. Check that all electrical connections are secure and properly seated

Verification

• Test low beam, high beam, and turn signal operation to confirm all functions work properly
• Visually inspect headlight assembly alignment with fender and grille
• Aim headlights using proper aiming procedure or have alignment checked professionally to ensure safe nighttime visibility
• Verify no warning lights are illuminated on instrument cluster

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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