DODGE CARAVAN HEADLIGHTS

I presume you have a service manual, though I may include brief pointers from it to make this advice more cohesive. Some of what I cover here is in the service manual if you can find it, often not in the section you'd expect it in - check more than one secton, such as the instrument panel and the section for a specific item sections.

These instructions are based on a 1993 and 1994 relatively high-trim model with Infinity sound system. They may be useful for all of the reflowed body style introduced in 1991 and produced through the 1995 model year.

TOOLS
You'll need a special tool to turn the knobs that hold the lenses in, otherwise you'll damage them. I cut a slot in a 1/2" nut driver. You'll want either a quite long shank on it - or extension on whatever your turn it with, or a slim lockjaw pliers to not interfere with the bottom of the lense. (All depends on what your nut driver looks like, best is one with hex shaft that you can use a ratchet wrench with hex adapter socket on, with an extension.)
And a T20 Torx screwdriver for the grill and turn signal assemblies.

The plastic lenses over the headlamp bulbs become abraded by sand or discoloured (especially if you run hotter than standard bulbs). Water can also get into some.

RE & RE
To replace the lenses you have to remove the grill and detach the turn signal housings. Beware that wiring is sometimes not long enough for setting them aside, you'll usually have to unfasten the turn signal bulbs from the housing.
And the outside temperature sensor attached to the grill is a bother to re-connect.

The lense is held in with three turn knobs, one on top and two on the bottom. You have to fit the turn tool straight over each, pushing hard against it so the tool does not slip off the knob and damage it.
Once turned 90 degrees so the tabs fit through the slot in the lense housing, wiggle the lense to get it off. If someone has damaged the tabs you may need to remove some material at their base to let them fit through the hole (a good wood chisel worked for me).

When re-installing the turn signal assembly, make sure its tabs at the inboard lower corner are in the slots there, and the flange for the stud at the top centre is on top of the body piece - some fiddling may be needed as clearance to the headlight lense assembly is small.

Congratulations, you've just completed another fiddling Chrysler job that takes far longer than it should.

STOPPING WATER
The expensive replacement headlight lenses I purchased let water get in, the originals did not. The water rises until the bulb shatters.
Applying silicone sealant worked for years, but you have to remember to reapply it as it will deteriorate.
I'm now trying a small drain hole in the bottom of the lense assembly.

REFINISHING LENSES
Refinishing the lenses is possible if the unclear condition is from sand abrasion. But it is much work. New ones are expensive.

There are kits of compounds to refinish lenses, I have not used them as I already had knowledge of compounds.

Otherwise get some fine, very fine, and extra fine polishing compound for use on plastic, and pads to rub with.
A rotary tool may be helpful, but do not overdo pressue as you don't want to discolour the lens from overheating it.
Obviously you start with the coarsest of those compounds to make the surface smooth, then go finer and finer until the lense is clear.

NOTE
In the centre of the turn button there is a Torx screwdriver slot, that is for adjusting aim of the headlights. Don't touch it.

© Keith Sketchley Page version 2019.09.02

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