Deuce Headlight Replacement

Published on August 13, 2014
Duration: 11:52

This guide details how to replace a burnt-out headlight on a Deuce and a Half military truck. It covers removing the old headlight, testing the vehicle's wiring harness with a multimeter, and modifying the wiring to accept a more affordable aftermarket headlight with a standard three-prong plug. The process emphasizes creating waterproof connections using heat shrink tubing and butt connectors for a durable repair.

Quick Summary

Replacing a Deuce and a Half headlight involves removing the bezel, disconnecting the old unit, and potentially adapting the wiring. Use a multimeter to test the vehicle's harness (16-ground, 17-low beam, 18-high beam). Affordable aftermarket headlights with three-prong plugs can be used by crimping butt connectors and applying heat shrink tubing for waterproof connections.

Chapters

  1. 00:30Introduction & Goal
  2. 00:37Removing the Bezel
  3. 01:12Old Headlight & Connectors
  4. 01:33Identifying Replacement Options
  5. 02:09Wiring Adaptation Strategy
  6. 02:25Testing Vehicle Wiring
  7. 02:54Confirming Headlight Issue
  8. 03:07Tools & Parts Overview
  9. 03:38Wiring Modification Process
  10. 04:49Securing Connections & Heat Shrinking
  11. 04:78Connecting to Vehicle Harness
  12. 05:26Plugging in New Headlight
  13. 05:47Reassembly & Final Check
  14. 06:04Testing the New Headlight
  15. 06:19Conclusion & Part Information

Frequently Asked Questions

How do you replace a headlight on a Deuce and a Half truck?

To replace a Deuce and a Half headlight, first remove the bezel by unscrewing three screws. Then, disconnect the old headlight's wiring. You may need to adapt the wiring to a new headlight with a standard three-prong plug using butt connectors and heat shrink tubing for a waterproof seal.

What are the numbered wires for the Deuce and a Half headlight?

The Deuce and a Half headlight wiring typically uses numbered connections: 16 for ground, 17 for the low beam, and 18 for the high beam. It's crucial to correctly match these numbers when installing a new headlight or adapting the wiring.

Where can I find an affordable replacement headlight for a Deuce and a Half?

While official Deuce and a Half headlights with specific connectors can be expensive, you can often find more affordable alternatives like the Wagner 4800, which is a 24-volt compatible headlight with a standard three-prong plug that can be adapted to your truck's wiring.

How do I ensure waterproof connections when modifying vehicle wiring?

For waterproof connections, use quality butt connectors to join wires and then slide heat shrink tubing over the connection. Use a heat gun to shrink the tubing tightly around the connector and wires, creating a sealed, weather-resistant joint.

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