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How to Replace Headlight 96-99 Dodge Caravan

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How to Replace Headlight 96-99 Dodge Caravan

Created on: 2012-02-17

Check out this video to learn how to replace the headlights in in your 96-99 Dodge Caravan.

  1. Note: DO NOT TOUCH the bulbs- the oil from your fingers will burn into the light and foul your bulb. Clean with rubbing alcohol and a soft cloth if the bulbs do get touched.

    step 1 :To replace just the headlight bulbs
    • Pop the hood and secure it.
    • Reach behind the headlight assembly.
    • Use a flat blade
    • Pull aside the rubber boot and unclip the retaining wire.
    • Remove and replace the bulb.
    • Anchor it with the retaining wire and seal it in with the rubber boot.
  2. step 2 :Remove headlight
    • Remove the four 10mm bolts securing the headlight assembly.
    • Use an 8mm socket and ratchet to remove the two bolts securing the washer bottle to access the bolts securing the headlight assembly easier.
    • On the driver’s side headlight, disconnect the negative battery cable and unbolt the fuse box to move it out of the way.
    • Use a 10mm socket and ratchet to do this.
    • Pull the headlight forward and out.
    • Disconnect the bulbs and wiring.
  3. step 3 :Install the new headlight
    • Plug in the wiring harness and bulbs.
    • Line up the assembly and bolt back in.
    • Bolt the grille back into place using your socket and ratchet.
  4. step 4 :Aim the headlights
    • Use a 4mm socket to adjust the headlights.
    • The low beam should be an inch below the height of the bulbs at 20 feet.
    • The high beams should be level with the bulbs at 20 feet.

Tools needed for replacement

  • Ratchets & Related

    Socket Extensions


  • Screwdrivers & Related

    Flat Blade Screwdriver

    Phillips Head Screwdriver

  • Sockets - Metric

    8mm Socket

    10mm Socket

Installation Video
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Brought to you by your source for quality replacement parts and the best service on the Internet. Hi. I'm Mike from 1AAuto. I hope this how to video helps you out and next time you need parts for your vehicle, think of Thanks.

In this video, we're going to show you how to service the headlights on this 1998 Dodge Caravan; same for any '96 to '99 Caravan or Voyageur. We do show you how to just replace the bulbs if that's all you need to do, as well as if you need to replace a clouded, broken or yellowed headlight with a nice new headlight from 1AAuto. We go over that whole procedure as well.

Tools you'll need: if you're just looking to replace a headlight, the passenger side headlight will only require the flat blade screw driver and the driver's side, you will need 10mm socket and ratchet or wrench to get some stuff out of the way. You also need an 8mm socket and ratchet or wrench to get the washer bottle out of the way on the passenger side if you're replacing the entire assembly.

If you're just looking to service the bulb, open up the hood. Here's the back of the headlight on the passenger side. Use a flat blade screw driver. Put it right in here so you can pry on the back of the connector and then also pull on the bottom of the connector. Then, your connector unplugs and then there's a ring here. Twist the ring, it comes out, and then your bulb ... You'll work it up and down a bit ... Comes right out. Put it back in. Make sure this tab here is on top. Make sure you work it back into the socket. It has an O ring on it. Put your retainer ring back on. Push it on and turn it to lock it. Then, reconnect your connector.

If you're just looking to access the bulb for this side marker parking light, in your wheel well, there's usually a plug on each side, you push it toward the front, turn it counter clock wise, pull it out, and then you can see right up in there is the plug. Reach up in. You have to turn it counter clockwise. Pull it out and then you can just pull the bulb out and then put it back in. You have to do it by feel. Put the plug back in.

If you want to remove and replace the headlight because it's broken, dull, or faded, there's going to be five fasteners. A 10mm bulb on top, three 10mm nuts on the backside on the back of the headlight. To get to those two that are in that washer bottle, there's an 8mm bolt that hold the washer bottle right there. We'll speed it up here as I use an 8mm socket with a ratchet and extension to remove that bolt that holds the radiator fluid bottle and move it out of the way a little bit. Now, I'm working a little faster. I use a ratchet and socket, 10mm, and get two of the nuts on the backside off. Then, remove the bolt that's on the top of the headlight. Now, I switch to a 10mm wrench to get in between that radiator bottle and get that last bolt off or that last nut. Once you loosen these nuts, you can usually just reach in with your hand and take them off by hand once they're loose.

Pull the light right out. Thread this one counter clockwise. Pull it out. If you want to replace this bulb, just pull it out and it pushes right back in. Then, disconnect your ... Disconnect your headlight, just reach in there with your fingers and the light comes out. You need to get this light socket off; you probably need a screw driver here. They're just little tabs. Push in on them. Pull the harness out. Push in on the other side. Pull it out. This is the new light from 1AAuto. If you've broken your assembly or whatever or if it's gotten cloudy and faded, it's going to go right in and mount just like the original. I'm just going to pull the plastic off a little bit here. Connect your bulb. Connect the headlight. There's a little pin, goes into the fender back there. Then, that lines up. Make sure everything else lines up.

Fast forward here again. I start the bolt on top and then I start all three of the nuts by hand. Tighten those nuts on the backside as much by hand as you can. Then, use your wrench to make everything tight. You don't want to ... You don't need to over tighten them, but make then nice and firm. Once you have the light installed, you'll need a 4mm socket. One adjuster's right here. Turn this counter clockwise and then you can see the little leveling ball there. As you turn it counter clockwise, it starts to aim the light up, which centers that ball between the lines. Then, there's another 4mm adjuster right here and that adjusts it left and right.

Something I forgot to say: your vehicle needs to be on a flat surface. I have it in a garage. Garage floor is usually nice and flat so you can make sure that leveling ball is indicating correctly. We'll speed it up here again as we put that radiator bottle back in place. Put the 8mm bolt back in and tighten it up.

Next, I'm going to show you how to access the driver's side headlight. I'm not going to do the whole procedure, but I am going to show you how to move that fuse block out of the way so that you can access it. You do need to remove the negative battery cable first. The driver's side's the same. You will want to move the relay box. That just involves removing two 10mm bolts. There's one there, and one there. Once you remove those, you push the box foreword and bring them back up and out and move it out of you way just like the radiator bottle on the passenger side.

We hope this helps you out. Brought to you by your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll free 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    Ratchets & Related

  • Socket Extensions
  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver
  • Phillips Head Screwdriver

  • Sockets - Metric

  • 8mm Socket
  • 10mm Socket

1996 - 1999  Dodge  Grand Caravan
1996 - 1999  Dodge  Caravan
1996 - 1999  Plymouth  Voyager
1996 - 1999  Plymouth  Grand Voyager
1996 - 1997  Chrysler  Town & Country
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