Chrysler Full-Size Trucks 1989-1996 Repair Guide

Headlights

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9

To access the bulb on 1994-96 models, you can reach behind the lamp, unplug and disconnect the halogen bulb.



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Fig. Fig. 1: Late models have bulbs which are replaceable from behind the lamp housing-1994 Pick-up shown

  1. On 1994-96 Pick-ups, open the hood for access to the mounting screws.
  2.  
  3. 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.
  4.  


WARNING
When dealing with replaceable halogen bulbs, never touch the glass. If you do, traces of oil from your fingerprints will cause premature failure of the bulb.

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Fig. Fig. 2: Unscrew the bezel attaching screws for headlight/turn signal access



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Fig. Fig. 3: Lift it away and set the bezel in a safe location with the mounting hardware


  1. Remove the headlight ring attaching screws and remove the ring. Do not touch the headlight aiming screws.
  2.  



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Fig. Fig. 4: Unscrew the sealed beam headlight-do not disturb the aiming adjustment screws



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Fig. Fig. 5: Remove the trim ring from the headlight

  1. Pull the lamp assembly out slightly and unplug the connector.
  2.  



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Fig. Fig. 6: Support the sealed beam in one hand and unplug the wiring by pulling on the connector



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Fig. Fig. 7: Exploded view of the combination headlight/turn signal/parking lamp assembly mounting-1994-96 Pick-ups

To install:

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

  1. Plug in the wiring to the light.
  2.  
  3. Install the headlight assembly.
  4.  
  5. If applicable, install the park and turn signal lamp.
  6.  
  7. Close the hood on 1994-96 Pick-ups.
  8.  



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Fig. Fig. 8: Exploded view of the headlight assembly-1989-93 Pick-ups and Ramchargers



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Fig. Fig. 9: Exploded view of the headlight and side marker assembly-Dakota models

AIMING



The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.

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.

Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal.

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

  1. Make sure all tires are properly inflated.
  2.  
  3. Take into consideration any faulty wheel alignment or improper rear axle tracking.
  4.  
  5. Make sure there is no load in the truck other than the driver.
  6.  
  7. The truck's fuel tank should be about half full.
  8.  
  9. Make sure all lenses are clean.
  10.  

To adjust:
  1. Park the truck on a level surface, with the fuel tank no more than 1 / 2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet (7.6m) from the wall.
  2.  
  3. If this is be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows.
  4.  
  5. Turn the headlights ON and mark the wall at the center of each light's low beam, then switch on the "brights'' and mark the center of each light's high beam. A short length of masking tape which is visible from the front of the truck may be used. Although marking all 4 positions is advisable, marking 1 position from each light should be sufficient.
  6.  
  7. If neither beam on 1 side of the vehicle is working, park another like-sized truck in the exact spot where the truck was and mark the beams using the same side light on that truck. Then switch the trucks so the truck being worked on is back in the original spot. The truck must be parked no closer to or farther away from the wall than the second vehicle.
  8.  
  9. Perform the necessary repairs, but make sure the truck is not moved or is returned to the exact spot from which the lights were marked. Turn the headlights ON and adjust the beams to match the marks on the wall.
  10.  
  11. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
  12.  

 
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