How-To: '06-'08 Headlight Disassembly/Paint

(Last time I checked they didn't have a 'how-to' for these year model headlights but now they do. I do it slightly different than the way already posted. You may want to discard this or possibly add it to the existing one, either way is fine with me)

For this project you're going to need a few things:

1.) Paint/clear coat
2.) Primer
3.) Masking tape
4.) Sandpaper(optional)
5.) 1 small flat-head screwdriver
6.) Black Silicone/Gasket Maker
7.) Oven

**Before you get started read through the whole how-to and make sure you understand each step so you don't get yourself in a bind later, I've done 6 lights using this method and it works for me. Good Luck.**

First thing you're gonna do is take your headlights off your truck. 2 screws under the hood and one nut inside the fender well hidden behind a rubber grommet should get it (I think they're all 10mm). Also, take the bulbs out of your headlight housing at this time. You also may want to take note of how the headlight will seperate where the clear plastic and the black plastic meet.

Ok with the both headlights now in the house, you should pre-heat your oven to 250 degrees(on bake).
Truck 105.jpg
The ovens I have used have had 2 trays so I had to remove the top tray to fit these massive lights inside the oven.
Truck 110.jpg
While the oven is pre-heating I usually grab a cookie sheet(?) and atleast one oven mitt, you can use whatever you want or is easier for you. When the oven reaches 250 degrees it's time to put the headlight on the cookie sheet and slide it in the oven
Truck 107.jpg
Now, let the headlights bake for roughly 10 minutes. (This is the only way I've tried it and I've never had the headlights 'fog up' and I can seperate the headlight in 1 shot so there is no need to re-heat the lights) When the 10 minutes is up the headligths WILL BE HOT! Use the oven mitt(s) and take the headlight out of the oven. You can take the whole tray out and set it on top of the stove but I usually put a couple of pot holders or a towel on the counter to set the headlight directly on.
This is a top view to give you an idea of what your trying to do.
Truck 120.jpg
Where the clear housing meets up with the black piece is where you need to slide in the screw-driver to seperate the housing. Note the tabs, try not to break these since you'll want to use these again later, they pry up pretty easy though so that shouldn't be a problem.
Take your time, do a good job without doing to much damage and make your way around the headlight seperating/prying apart the headlight. If it becomes too tough to seperate, then put it back in the oven after it's cool to the touch for another 10 minutes and repeat as necessary(The first set I did was on my truck and I did have to re-heat them once, but the next 2 trucks I've done since then I've gotten apart in 1 shot( it's no big deal just make sure they are atleast cool to the touch before re-heating ). Once you seperate the clear housing from the black backing, the chrome piece with the reflector just pops out(take note of how it pops out since you're going to have to reverse this process without scratching your fresh paint job later)and it should look something like this.
Truck 111.jpgTruck 117.jpgTruck 113.jpg
**If you have other plans for the reflector on the side of your blinker besides painting over it, now would probably be a good time to take it out (4 little clips will do it)**
Ok now the easy part, prep and painting. Sanding, the first 2 trucks, I did not sand the headlights but on the last one I did. I think you could by-pass this step, I couldn't tell a difference except that you definitely need to come back with primer if you do because chrome comes off very easily and the plastic scratches pretty easy and I was using 1500 and 2000 grit sand paper so you want to make sure that if you sand to prime it before you paint to help smooth out you finish. Next step would be masking off the area(s) you don't want painted. Since the headlight 'bowl' stays attached to the black plastic piece, all I worry about taping off is the reflector 'bowl'.
I put a few light coats of paint and then a few heavier coats of paint. Waiting about 10 minutes between coats. I come back with the clear coat immediately after my last heavy coat of paint to lock in the shine. If you have a different technique then by all means use it, I'm not a professional.
Anyway, however you decide to paint, when you're done it should look like this
Truck 115.jpg

The directions on the paint can said to wait an hour before handling, I usually wait atleast 2 or 3 just to be on the safe side. I would definitely wait an hour though. Now it's time to start putting this thing back together and wrap this job up. Go back inside your house (you did paint outside or in a shed or something right?) and very carefully slide your freshly painted pieces back inside the clear housing. I cannot stress enough to take your time and if it's not going in, carefully slide it out and try again, if not you will be looking at some scuffed paint.
At this point I pre-heat the oven at 250 again. While waiting I put a nice bead of the black silicone in the groove that the clear housing goes into. When the oven is ready I put only the black plastic piece with the headlight bowl and the fresh bead of silicone back into the oven, again for 10 minutes. After 10 minutes pull the black piece back out (don't forget your oven mitt(s)) and slide the clear housing (which already has the painted piece locked inside of it) back into the grooves. It sounds easier than it is, if possible I suggest having somebody help out with this step but it can be done by yourself. Once you get it in place, and sometimes it doesn't cooperate, lock the tabs back down on the clear housing.
I added another bead of black silicone around the edges when I was done to get it as close as I could to a factory like seal. If you skip this step then you can put your headlights back on your truck now, if you do add another bead of silicone wait until it dries because it gets a little messy. I only added the last bead of silicone to the last truck I did so I'm not sure how much it helps in preventing the light from fogging up like I find mine from time to time first thing in the morning, it's nothing that can't be cured by turning your headlights on for a few minutes though so this last step is optional. That's about it....here is what I ended up with.
Truck 106.jpg

Truck 109.jpg

Truck 122.jpg

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Truck 118.jpg

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I'll post pics of the last truck I did this past weekend this evening, anything I missed, skipped or any questions let me know.

looks good. Got an extra set of 06-08 lights laying around?

I don't have any stockers but I do have an extra set of projectors sitting at the house.

Here's the pics of the latest truck...

mattheadlight2.jpg

mattheadlight1.jpg

mattheadlight3.jpg

Who's truck is that?

Matt from Shreveport(Matt99). It's his lights in the pics in the "how-to", the only difference between the two black sets that are pictured is that Matt had me use a black paint with a metal flake in it and the other set I just used gloss black. Here's a link to a thread he started about his painted headlights http://www.dodgetalk.com/forums/showthread.php?t=254690

Actually, I'd like to try doing another color besides black again.

Well, if ya get bored one weekend around mid june...come on up to Harahan. We can do mine But they will be black

You can't go wrong with black.....I've got weekends off for now, never know how long it's gonna last but you never know.

Great writeup and yup, it was my lights! I painted my antenna/antenna shroud today and still cannot paint right. I just need to go take a night class on body shop.

My lights look great, I went ahead and put another bead of silicone on the lights. Just extra security and I had a old tube lying around. I love the lights though, had a compliment last night!

Good write up.Alot better detailed than the one I posted.This should replace it.

hey maybe we can do a set of silver

They look great! I'm wanting to do mine in black, but i have 06 lights. I also noticed you got rid of the amber parking lights? Is that legal?

Very nice man take this write up and my how to tint tails and you could have a pretty pregressive weekend on modding a truck

Originally Posted by matt99

Great writeup and yup, it was my lights! I painted my antenna/antenna shroud today and still cannot paint right. I just need to go take a night class on body shop.

My lights look great, I went ahead and put another bead of silicone on the lights. Just extra security and I had a old tube lying around. I love the lights though, had a compliment last night!

Cool, I'm glad you like em.

Originally Posted by CRMRAM

Good write up.Alot better detailed than the one I posted.This should replace it.

I appreciate that but if I would've seen your how-to before I made my mind up to do it, I wouldn't have done it. I wasn't trying to step on anybody's toes .. I Think it needs more pics of the actual taking apart and putting the headlights back together but I didn't have anybody there to 'man' the camera anyway, maybe next time.

Originally Posted by BIGJOHNSON

hey maybe we can do a set of silver

Let me know

Originally Posted by Got_Hemi44

They look great! I'm wanting to do mine in black, but i have 06 lights. I also noticed you got rid of the amber parking lights? Is that legal?

I didn't look into it but I don't see why it wouldn't be because he still has the parking/running light with his blinker(just like my '07). I think it should be illegal to have that amber strip at the bottom to begin with . If you're still reluctant, you should try some niteshade on it or check with DeMoN-HeMi, he know's every trick in the book.