Dodge Ram Sport Headlight Conversion

Dodge Ram Sport Headlight Conversion

Date: 10/19/2008

This is a description of what's needed to convert a '94 - '02 Dodge Ram 2500/3500 from stock OEM headlights that use a 9004 bulb on each side to aftermarket Sport Headlight units that use two bulbs on each side - a 9004 and a 9007 bulb on each side.

A caution - there are aftermarket headlight units sold that are called "Sport Headlights" but that only use one bulb on each side. These may have clear lenses, or may be called Euro lights, but with only ONE bulb the light output will be similar to the OEM non Sport headlights.

Here is a picture of the two bulb Sport Headlight units.

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As far as I know (and what DO I know?) all of the aftermarket two bulb Sport Headlight units are manufactured by a source called "DEPO", no matter who sells them.

A good source for these DEPO units is an eBay seller that uses the eBay user name of headlightsdepot. They usually have a "Buy it Now" auction running with a price of $189 plus $28.95 shipping. This includes all bulbs and sockets, 2 9004, 2 9007, and 2 corner lights.

Search eBay for "Dodge Ram Sport Headlights". You can find a pair including bulbs for under $220 shipped.

I have seen other eBay sources at slightly lower prices, but these did not include bulbs.

Now as far as wiring up the 4 bulbs, 2 on each side, to do it right you do not want to power these directly off your OEM headlight switch. Running the extra current through the OEM switch is not good for long switch life. Believe me on this.

You can wire it up yourself using relays, but a good solution is to use the dual wiring harnesses sold by SUVlights. This is two wiring harnesses, one for each side. It powers the bulbs direct off the batteries via relays, each side has a relay for both high beam filaments and a relay for both low beam filaments. It is very well done, is waterproof, and includes fuses on the +12 circuits. Price is $133 for everything. That sounds like a lot, but it's very well done and is complete.

Dodge started offering Sport Headlights in '01 (I think, I'm not sure).
For the Rams from '94 through when Dodge first offered Sport headlights, you have to modify the inside of the headlight buckets to have clearance and access to the second bulb's socket. This is done pretty easily with a sawzall or air operated saw. This is your chance (excuse) to spend another $90 for an Ingersol Rand air operated sawzall type saw.

Anyway, the pictures below show the inside of the stock headlight bucket and what you have to cut away for clearance and access. With the right saw, it takes about 30 minutes.

I have the DEPO lights on my '96 truck, and I have had no problems. I have heard that the rubber welt that seals the grill to the inside side of the headlight deteriorates with time. If that happens, here are the MOPAR part numbers for the OEM rubber welt parts:
* 55076746 WELT, Headlamp To Grille - Right
* 55076747 WELT, Headlamp To Grille - Left

Inside of stock headlight bucket	Location of second bulb's socket	Clearance and access opening cut larger
Access opening seen from inside engine compartment.	Finished installation with Sport Headlights	View of stock (on top) and sport headlights.

The above six pictures taken from Turbo Diesel Register web site.

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