My passenger side headlight went out, tried to follow the factory service manual (FSM) replacement instructions. It said replacing a bulb required removal of the whole assembly. The FSM is not real clear, it says to remove the bolts holding the assembly to the inner fender. There is a drawing, which is of limited help. It does not say how many of those bolts there are, or where they are located. I did a search of these forums and found old threads on the subject, which stated that there are three, top and bottom on the grill side, and bottom on the outside. I found those three and have removed them, but still cannot pull the assembly out. Something seems to be holding it up at the top outside. The old threads state that to remove the assembly one of the smaller lights needs to be first removed from the assembly. The FSM did not mention this. There are three lenses, the main headlamp, a small curved triangular lens (also clear), and the long yellow lens that curves around under both of the clear top lenses. Has anyone here run into this problem? Do I need to partially disassemble the assembly in order to get it out? If so, which part needs to come off? The FSM says to pull firmly after removing the bolts. I have pulled pretty firmly, but a lot of these parts are plastic, and I don't want to break anything. Thanks.
01 Durango headlight replacement
Tom Morgan
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My passenger side headlight went out, tried to follow the factory service manual (FSM) replacement instructions. It said replacing a bulb required removal of the whole assembly. The FSM is not real clear, it says to remove the bolts holding the assembly to the inner fender. There is a drawing, which is of limited help. It does not say how many of those bolts there are, or where they are located. I did a search of these forums and found old threads on the subject, which stated that there are three, top and bottom on the grill side, and bottom on the outside. I found those three and have removed them, but still cannot pull the assembly out. Something seems to be holding it up at the top outside. The old threads state that to remove the assembly one of the smaller lights needs to be first removed from the assembly. The FSM did not mention this. There are three lenses, the main headlamp, a small curved triangular lens (also clear), and the long yellow lens that curves around under both of the clear top lenses. Has anyone here run into this problem? Do I need to partially disassemble the assembly in order to get it out? If so, which part needs to come off? The FSM says to pull firmly after removing the bolts. I have pulled pretty firmly, but a lot of these parts are plastic, and I don't want to break anything. Thanks.
You can replace main headlight bulb from backside. I can't show pic currently cuz I'm at work. You can unscrew a black screw type housing which than allows you to pull harness and bulb out. Sorry for bad description, hopefully you can find it
To remove the headlight you need to remove the parking turn signal light assembly first. Its held on by a single T-10 torx screw located at the corner of the headlamp and the side triangle. Remove that...its one assembly and then you'll have easy access to the 3 screws for headlamp removal. Very easy. It comes out toward the front.
Make sure you remove the rubber seal from the turn signal light assembly on the inside where hood closes.
Tool needed; T-10 torx screwdriver..available at your local parts store.
Make sure you remove the rubber seal from the turn signal light assembly on the inside where hood closes.
Tool needed; T-10 torx screwdriver..available at your local parts store.
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Chase, thanks, I did manage to get the turn signal and side marker light assembly out with some wiggling. The main assembly still didn't want to come out, but with the ability to move it around farther, I was able to see the problem. There was a guide pin in the upper left. It is pointy and is able to pivot around as the headlamp is adjusted. And it was really stuck in there. With the improved access I was able to use a large flat head screwdriver to pry it out.
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LOL! Yeah, mine have been out more than a few times so they almost fall out by themselves once I remove the bolts.
Anyhow...good job.
Its a little tricky getting the guides for turn signal side lights back in....but easy to figure out when looking at them.
Anyhow...good job.
Its a little tricky getting the guides for turn signal side lights back in....but easy to figure out when looking at them.
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OK, now that I have managed to get the whole assembly (assemblies) out, comes my next problem. My headlight lenses are very cloudy, as they tend to get when they reach legal drinking age. Months ago, I bought a set of replacements, and a headlamp going out was the push needed to get to it.
The FSM is pretty worthless on this subject. It just gets down to the level of the headlamp and frame assembly, the turn signal, and the corner lamp. It never discusses separating the adjustable headlamp from the fixed frame, which is what many people will need to do to replace their foggy headlamp housings. The headlamps are being sold by themselves, without the fixed frame. I just bought a pair, and I'm sure many of you have also.
So I took a look to see what is needed to put a new adjustable headlight housing on my old, fixed frame. Seemed pretty simple at first, three adjustment screws, with T15 heads. But two of the screws are accessible, while the third, the one on the bottom between the slots for aligning the turn signal, is blocked off. You can't get to the head of the screw. Not only can I not figure how I to get that screw out, I also can't figure how Dodge assembled it in the first place. The new headlight housing has the same block-off. Has anyone run into this? I suppose the obvious solution is to drill a hole through the fronts, or just cut it out, but that still doesn't explain how this was put together at the factory.
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The FSM is pretty worthless on this subject. It just gets down to the level of the headlamp and frame assembly, the turn signal, and the corner lamp. It never discusses separating the adjustable headlamp from the fixed frame, which is what many people will need to do to replace their foggy headlamp housings. The headlamps are being sold by themselves, without the fixed frame. I just bought a pair, and I'm sure many of you have also.
So I took a look to see what is needed to put a new adjustable headlight housing on my old, fixed frame. Seemed pretty simple at first, three adjustment screws, with T15 heads. But two of the screws are accessible, while the third, the one on the bottom between the slots for aligning the turn signal, is blocked off. You can't get to the head of the screw. Not only can I not figure how I to get that screw out, I also can't figure how Dodge assembled it in the first place. The new headlight housing has the same block-off. Has anyone run into this? I suppose the obvious solution is to drill a hole through the fronts, or just cut it out, but that still doesn't explain how this was put together at the factory.
Just clean and defog your lenses. There are kits for doing that.
Doesn't it just pull out? Been too long since I replaced one...and my '01 is at school with my son so I can't check.
Seem to remember just pulling it out...assuming you have factory replacements should be able to see how the bottom set screw would go back in? Or does it install from the back side?
Seem to remember just pulling it out...assuming you have factory replacements should be able to see how the bottom set screw would go back in? Or does it install from the back side?
My right side headlight bulb went out, I tried to change bulb myself for quite awhile but could not even get my hands into the small space to do so. Finally took Durango(2003 SLT)to a dealer, fixed in 10 minutes, cost was $150. No problems since and to me worth the money just to end the frustration and get the car on the road.
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Wanted to give an update for those who replied with info, and any who might be facing the same problem. I ended up just replacing the bulb on the passenger side and putting the assembly back together, fogged glass and all. What I can tell from having dug in this far, is that Rock Auto will sell you the headlight-only assembly, but I don't know that it is actually a usable product. Besides the one adjuster screw that I discussed being blocked off, I don't see how any of the three could be transferred to a new headlight-only assembly. They seem to be locked in. This is probably why the FSM, along with online videos, only discuss how to replace the whole assembly. Also learned that you do need to remove the one T10 screw and remove the orange assembly, to give you room to move, despite what the FSM says. The video from 1A auto parts (A1?) shows how you need to pry that top outside pointy guide loose. I have seen other useful guides from these guys.
Thanks to those who replied. My advice to anyone in this situation is to not buy the headlight-only assemblies, even if you (like me) think that is the only one needing replacement, so you can save some money. And I still challenge anyone to explain to me how that blocked off adjustment screw was set at the factory. 🙂
Thanks to those who replied. My advice to anyone in this situation is to not buy the headlight-only assemblies, even if you (like me) think that is the only one needing replacement, so you can save some money. And I still challenge anyone to explain to me how that blocked off adjustment screw was set at the factory. 🙂
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