2nd Gen Non-Engine/Transmission Headlights

[flyrod40]

Hi Guys and Ladies. Old topic, but after searching, many of the links no longer work. Our Ram is a '97 2500 diesel. Headlights are terrible. I have replaced the housing many times with new OEM housings and finally Sylvania zXes but nothing really helps the lack of light. I have been reading about the sportlight conversion, but as I mentioned many of the links are broken. Are these the headlights I need? https://www.headlightsdepot.com/199...-halogen-headlights-kit-sku-cs163-b001ph.html

I'm not too good with electrical projects, but I think I also need the relays some people talk about. Can someone please explain where I get them and how they are wired?

Thanks in advance.

 

[BigPapa]

I think this was the last good thread on it.

https://www.turbodieselregister.com/threads/best-headlights.272266/

 

[BarryG]

The sport lights are the way to go. Years ago when I converted my 01 it was either Depo or Tye brand that I used cant remember now. 15 years later they are still working fine. I think I bought them through Genos Garage. For the harness I ended up buying one from Daniel Stern. It was a top quality harness and pretty much plug and play. I just took a quick look and he is still around and selling stuff
https://www.danielsternlighting.com/products/products.html I believe the one you want is the RIKRAM harness. He was very helpful to me. He also had some specific bulbs that he recommended, might be worth an email or call to him to see what it is today. Many folks built there own harness but I was in a time crunch, didn't have to chase down the stuff and for me it was worth it to pay him the money for the harness and as I said it was top quality. Unlike some of the others that were or are still out there.

I cant remember what year it changed but pre whatever year, actually pre sport model years, you could still switch to the sport lights but you had to do a bit of trimming with a sawzall to get them to fit. It was not hard at all I helped a guy do it and it was a few minutes work to open teh bucket a bit so thedual buld ones would fit.

 

[petersonj]

Here's the link to Geno's Garage for the "Brite Box" relay kit. They also make one w/fog lights, as well.

https://www.genosgarage.com/product/bb-4-2-7-4b/accessories-lighting

About the Headlights Depot in your link - I would be very concerned about the quality of the reflectors in those headlights for that price.

Geno's Garage sells Depo brand (not Headlights Depot products). You will pay much more, but the quality for the Depo sport headlights is close to OEM quality. I know, because I have tried the cheaper brands and they failed miserably. The Depot sport headlight is excellent in covering the roadway and the side of the roadway - both low and high beam. The low beam has a very good cut-off to not blind oncoming drivers.

You will have to purchase each headlight independently:

https://www.genosgarage.com/product/dep-3341102rusc/lighting

Here is the "Installation instructions from Geno's. The instructions include the necessary cutting that is needed on the older 2nd generation trucks:

https://s3.amazonaws.com/cdn.genosgarage.com/downloads/TechPDF/TDR77_HeadlightConversion.pdf

If you do it right the first time, you will not regret making the conversion.

- John

 

[BigPapa]

I went with Dorman Sport Assemblies when I did mine. Never had a problem with them and fit was perfect. Full factory adjustments.

 

[flyrod40]

Guys, Thank you very much. I think I have the info I need. I cannot wait to start and finish this project!

 

[BigPapa]

Another thing I just thought of. I'm not sure on your '97, but on my '98 I had to cut a hole in the core support on one side. I thought I had a pic but can't find it.

 

[flyrod40]

Several follow up questions: 1. Should I disconnect the negative battery terminals before starting the project?
2. I don't have a sawzall. Should I buy one or can I make the cuts with a hacksaw and/or file?
Thanks again.

 

[Cummins12V98]

I believe years ago many were using a holesaw. Be ware you better have a beefy drill and strong wrists!!!

 

[petersonj]

It's always a good practice to disconnect both grounds before starting a project like this. It will take care of Murphy.

Be sure to let us know how the project turns out and what you think about the performance of your new lights.

- John

 

[BigPapa]

2. I don't have a sawzall. Should I buy one or can I make the cuts with a hacksaw and/or file?.

If I remember correctly, I used a cut-off wheel in my 4” angle grinder. There’s already a hole there, you’re just enlarging it.

This is from Geno’s.

https://blog.genosgarage.com/wordpress1/2017/02/how-to-dodge-ram-sport-headlight-conversion/

It has pics of one they cut out. I didn’t cut out NEAR as much as they did.

 

[flyrod40]

Thanks again guys. I do have an angle grinder. I'll give that a try.

 

[Shelby Griggs]

Yes, sport conversion is a good way to go along with an aftermarket harness, I am using the Daniel Stern one. I have had Depo housings, currently some knockoff from carparts.com, pretty cheap, but I figure they can be replaced every 2-5 years. None of them seem to last long for me.

I am watching the aftermarket, Alpharex (link is for their newer Ram lights but 2nd gen is rumored to be a similar Nova projectors) is rumored to be releasing a complete LED projector housing in Q1 of 2025. If like their other products it will be expensive at around $1000.

I ran LED bulbs (yes, I know better) for the last couple years, but when I had one of the bulbs die, I went back to halogen, while the LED's in a reflector housing were not the best on low beam (poor pattern), on high beam things were very visible down range about 2000 feet. I had to adjust them so much to not blind other drivers that the low beams just didn't do well, but seeing what an LED can do makes me anxious for the rumored Alpharex release. I will say if you do decide to be one of those people that puts LED bulbs in a reflector housing, spend about $100+ a bulb to get one of the higher end offerings that mimics the placement of a halogen filament and then adjust the heck out of the aim so you don't blind others (too much). I didn't get flashed at all, BUT my low beam pattern sucked because I tried to be considerate.