How to Install AlphaRex NOVA-Series Headlights (880566) on a 2002–2005 Dodge Ram

Upgrading your 2002–2005 Dodge Ram 1500, 2500, or 3500 with AlphaRex NOVA-Series Projector Headlights (Part #880566) not only enhances your truck’s appearance but also improves nighttime visibility. The good news? This is a DIY-friendly install that requires only a few common tools and some patience.

Follow this detailed walkthrough for a step-by-step installation guide, complete with images to help along the way.

Tools You’ll Need

• Plastic Panel Popper
• 1/4” Ratchet
• 1/4” Extension
• Power Tool (optional – be careful not to overtighten)
• Phillips Screwdriver
• Flat Screwdriver
• 10mm Socket
• 4mm Socket

Safety Note: Always disconnect the negative battery terminal before working on your truck’s electrical system.

Removing the Factory Headlights

Disconnect the Negative Battery Terminal

Before anything else, disconnect the negative battery terminal to prevent electrical shorts or accidental sparks.

Remove the Headlight Bolts and Screws

• Open the hood.
• Remove two 10mm bolts securing the headlight.

Use a screwdriver to remove the two plastic clip retainers.

Using your extension, remove the 10mm bolt at the bottom of the headlight.

Repeat these steps on the other side.

Remove the Headlights

With all bolts removed, use a panel popper tool to carefully pry out the headlights. Pull them straight forward to release.

Disconnect the Wiring

Unplug the light sockets to free the headlight assembly completely.

Installing AlphaRex NOVA-Series Headlights

Route the DRL Wires

• Start on the driver’s side (closest to the battery and fuse box).
• Connect the red wire to the battery’s positive terminal.

• Connect the black wire to the negative terminal or one of the 10mm firewall bolts.

• Guide the DRL wires across to both sides.

Tap the Fuse

• Open the fuse box.
• Locate Fuse #29 (20A) – this is for the cigarette lighter.

• Crimp the gray wire from the harness to the fuse tap, then connect it to Fuse #29.
• Route the wire neatly and replace the fuse box cover.

Plug In and Install the Headlights

• Connect all harness wires into the AlphaRex headlights.
  ⚠️ Important: Do not use dielectric grease on these connectors.

• Secure the harness to the daytime running light connection.
• Repeat on the passenger side.
• Reinstall the headlights by reversing the removal steps (bolts, clips, and screws).

Test Your New Headlights

Before closing up, test all functions:

• Low beams
• High beams
• DRLs
• Turn signals

Adjust Headlight Aim

• Park your truck about 25 ft from a wall on level ground.
• Use the adjusters to fine-tune both vertical and horizontal alignment.
  This ensures optimal visibility without blinding oncoming drivers.

Congratulations! You’ve successfully installed AlphaRex NOVA-Series Projector Headlights (880566) on your Dodge Ram. Enjoy modern styling, improved performance, and a fresh new look for your truck.

👉 Looking for more AlphaRex products? Check out our AlphaRex collection.