Chrysler Full-Size Trucks 1967-1988 Repair Guide

Headlights

Print

REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

  1. Remove the headlight bezel attaching screws and remove the bezel. On some models it may not be necessary to remove the bezel, depending on whether the headlight retaining ring is accessible.
  2.  
  3. Remove the headlight ring attaching screws, then remove the ring. Do not touch the headlight aiming screws.
  4.  
  5. Pull the sealed beam out slightly and unplug the connector.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the retaining ring from around the bulb



Click image to see an enlarged view

Fig. Fig. 2: Pull the bulb out slightly to disconnect it from the wiring



Click image to see an enlarged view

Fig. Fig. 3: After installing a new bulb, position the retaining ring and tighten the screws



Click image to see an enlarged view

Fig. Fig. 4: Headlamps are designed as either single or dual lamp assemblies, and may be round or rectangular

To install:
  1. Fasten the electrical connector, then position the sealed beam in place.
  2.  
  3. Install the retaining ring and the headlamp bezel, if removed.
  4.  

As long as the adjusting screws were not moved, the headlight will be held in proper adjustment by the retaining ring.

AIMING RECOMMENDATIONS



See Figure 5

Before making any headlight adjustments, perform the following preparatory steps:

  1. Check the operation of the dimmer switch; is it working properly-
  2.  
  3. Check for badly rusted items on the headlamp assembly; it would be advisable to replace any parts that are severely rusted.
  4.  
  5. Make sure your truck is on LEVEL ground.
  6.  
  7. Make sure all tires are properly inflated.
  8.  
  9. Take into consideration any faulty wheel alignment or improper rear axle tracking.
  10.  



Click image to see an enlarged view

Fig. Fig. 5: Headlamps can be aimed by turning the adjusting screws; however, you should have the proper aiming equipment to do the job correctly

  1. Make sure there is no load in the truck other than the driver.
  2.  
  3. Make sure all lenses are clean.
  4.  

Each headlight is adjusted by means of two screws located at the 12 o'clock and 9 o'clock positions on the headlight underneath the trim ring. Always bring each beam into final position by turning the adjusting screws clockwise so that the headlight will be held against the tension springs when the operation is completed.

ADJUSTING AND AIMING



Check with your local authorities before performing this procedure. Most areas have standards for proper adjustment. We recommend, for safety, that the adjustment always be checked by a reputable shop.

The use of SAE approved equipment is preferred to achieve exact adjustment of the headlamps, although a fairly accurate method of adjustment is as follows:

  1. Position the vehicle approximately 25 ft. (7.6m) from a screen or wall, and ensure that the vehicle is facing the wall straight.
  2.  
  3. Measure the height from the ground to the center of the each headlamp, and note these figures.
  4.  
  5. Measure the same distances from the ground (as recorded in Step 2) and mark the appropriate spots on the screen or wall with chalk. Ensure that the marks are straight ahead of each headlamp.
  6.  
  7. Turn the headlamps on and compare their beams with the marks previously made.
  8.  
  9. If properly adjusted, the beams should shine from approximately 2 in. (51mm) above to 2.5 in. (63.5mm) below the center chalk marks.
  10.  
  11. Turn each vertical (top) adjusting screw as needed to correct the adjustment. The best overall setting is 1 / 2 -1 in. (13-25mm) down for low beams, and 0- 1 / 2 in. (0-13mm) down for high beams.
  12.  
  13. Now check the horizontal aim. If properly adjusted, the left-side beams should be 4 in. (102mm) to the right of the center mark previously made, while the right-side beams should be 4 in. (102mm) to the left of the center mark.
  14.  
  15. Turn the horizontal (side) adjuster screw as needed to obtain the correct setting.
  16.  
  17. After completing an adjustment, recheck the previous adjustment, since the headlamp's aim will change slightly (up or down) when turning the opposite adjuster.
  18.  

 
label.common.footer.alt.autozoneLogo