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Replace the DRL bulb today

13756 Views 16 Replies 13 Participants Last post by  dov tayles
I thought I would post a brief description of how to replace the daytime running light (DRL) bulb on a Promaster. I searched Youtube and could only find videos for the replacement of the headlight bulb. I guess either I couldn't find it, or because DRL's are only required in Canada nobody has documented it.

The process involves removing the entire headlight assembly, after removing the upper and lower trim pieces. Refer to this video for this step. It's actually quite easy, just be careful removing the lower trim as the clips are apparently very prone to breaking, mine did not break. Tools required: Phillips screwdriver (3 screws for trim pieces) and 10mm socket for the 3 bolts that secure the headlight assembly.


Once the headlight is out, unscrew the large cover that provides access to the headlight and DRL bulb, this is simply a slight counter clockwise turn by hand.

Actual DRL bulb removal
- The bulb holder is shown in the picture. It requires a slight counter-clockwise turn, I had to use pliers with quite a bit of force. I was actually worried it would break something, but it didn't and then popped out. You may have to use pliers again to re-insert.
-The bulb simply pulls out to replace. The part number is 4B06 and it cost me $7.45 plus tax in Canada.

Process was quite straightforward and took about 30 minutes.

Funny thing though. While putting it all back together I said to myself, "self, shouldn't I test this before reassembling everything". I jumped in the van, turned on the ignition, with the parking brake released (the parking brake disables the DRLs) and the warning light came on the dash and the bulb was still dark! I looked at the light and banged it with my fist, the light came on!

I believe a dealer would charge at least and hour labour to do this, it's quite simple really.

Shaun

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I thought I would post a brief description of how to replace the daytime running light (DRL) bulb on a Promaster. I searched Youtube and could only find videos for the replacement of the headlight bulb. I guess either I couldn't find it, or because DRL's are only required in Canada nobody has documented it.

The process involves removing the entire headlight assembly, after removing the upper and lower trim pieces. Refer to this video for this step. It's actually quite easy, just be careful removing the lower trim as the clips are apparently very prone to breaking, mine did not break. Tools required: Phillips screwdriver (3 screws for trim pieces) and 10mm socket for the 3 bolts that secure the headlight assembly.

https://www.youtube.com/watch?v=neE0ur7qnqc

Once the headlight is out, unscrew the large cover that provides access to the headlight and DRL bulb, this is simply a slight counter clockwise turn by hand.

Actual DRL bulb removal
- The bulb holder is shown in the picture. It requires a slight counter-clockwise turn, I had to use pliers with quite a bit of force. I was actually worried it would break something, but it didn't and then popped out. You may have to use pliers again to re-insert.
-The bulb simply pulls out to replace. The part number is 4B06 and it cost me $7.45 plus tax in Canada.

Process was quite straightforward and took about 30 minutes.

Funny thing though. While putting it all back together I said to myself, "self, shouldn't I test this before reassembling everything". I jumped in the van, turned on the ignition, with the parking brake released (the parking brake disables the DRLs) and the warning light came on the dash and the bulb was still dark! I looked at the light and banged it with my fist, the light came on!

I believe a dealer would charge at least and hour labour to do this, it's quite simple really.

Shaun
Excellent and very clear! Thank you very much ! (From another Canadian concerned by this replacement ...)
Has anyone thought of replacing standard bulbs with LEDs? It seems to be much more efficient (lumen) and especially last much longer.
 

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Research CANBUS and LEDs. What we often refer to as CANnotBUS. It is a pain but you can get brighter lights with longer life but CANnot get lower wattage generally. Lumens are regulated by the traffic safety administration for good reasons.
 

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Discussion Starter · #5 ·
It's funny you ask that. I had to replace the same DRL bulb again this week and noticed that the socket the bulb fits into is damaged to the point where the bulb wiggles loose. So much so that it loses contact and doesn't stay lit. My temporary hack was to solder the bulb in place. I don't think this will last. I called my dealer and the only way to fix this is to order an entire headlight assembly, what a waste! $450 cdn IIRC.

Like BillD I would like to find a source for the small parts inside the headlight. Thanks.

PS, I had to come back to this thread to refresh my memory on the process of replacing the DRL. Glad I wrote it! :)

Shaun
 

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ANyone ever found a new CEMM Thome connector for the ones we break taking them out?
They were made in Monterrey MX but I think another company has taken over the automotive part
Greetings! Apologies for resurrecting this old thread. We just picked up a used 2018 PM 3500, and one of the DRLs were "out". turns out that this connector had been broken in the past (maybe when the actual bulb was replaced), to the point where the long handle in the back had been ripped off so looks like they just stuck it in with a pair of pliers.

The plastic housing where the bulb's terminal set against is loose, which causes an intermittent connection. We'll hack something together for now so it works, but would love to grab a hold of the replacement part for this if anyone has a lead! :) otherwise, may look into 3d printing it or something... ;)

thanks in advance!
 

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Has anyone in the US added DRL to there ProMaster? I see where the light would be but not sure if there is space inside the headlight to add a bulb. Too costly to purchase the Canadian headlight assembly.
 

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ANyone ever found a new CEMM Thome connector for the ones we break taking them out?
They were made in Monterrey MX but I think another company has taken over the automotive part,
Did you ever end up finding this? I went to replace mine and that same connector snapped. Or is there an aftermarket version that would fit the assembly easy by rewiring to that assembly? It seems crazy to buy a whole new headlight. :(
 

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ANyone ever found a new CEMM Thome connector for the ones we break taking them out?
They were made in Monterrey MX but I think another company has taken over the automotive part,
Did you ever end up finding this? I went to replace mine and that same connector snapped. Or is there an aftermarket version that would fit the assembly easy by rewiring to that assembly? It seems crazy to buy a whole new headlight. :(
 

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I needed to replace a dead daytime running light. I took the assembly off, opened it up, twisted that long tab worrying it might break. It broke. I tried pliers to get the socket out and just ended up destroying it. For now I have just disabled the DRLs and am wondering about a new headlight assembly.
 

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I needed to replace a dead daytime running light. I took the assembly off, opened it up, twisted that long tab worrying it might break. It broke. I tried pliers to get the socket out and just ended up destroying it. For now I have just disabled the DRLs and am wondering about a new headlight assembly.
If found a headlight assy with the DRL, at a reasonable price, please give the source.
 

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Passenger side DRL is out. Very good You Tube video by DM DM gives me hope. ProMaster Forum content is ominous. Am familiar with complicated headlight assembly removal, after installing higher intensity bulbs from Open Glass Mods (found on this Forum) so only obstacle to success appears to be turning the DRL holder CCW to remove it from the assembly. Will report on what transpires when I get into the headlight assembly.
 

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Discussion Starter · #16 ·
After several replaced DRL bulbs I decided to use an LED version. The only downside is the "bulb out" warning light remains lit on the dash. I solved that with some black electrical tape. I smile everytime I pass another PM on the road with a burned out DRL bulb.
 

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My solution has worked so far. I've had both incandescent DRL bulbs burn out. When I replaced the first one, the long plastic piece that functions as a grip to remove it broke off. I replaced the bulb and applied dielectric grease to both the bulb, and the OUTSIDE of the socket so that it twists in and out easily. I used a plastic welder [from Harbor Freight] to reattach the handle. When the other side did the same, I repeated the process. So far, so good. Also, Rock Auto sells "long life" replacement incandescent bulbs. I don't know yet if they last longer or not. I am not as tolerant as ShaunB of a "bulb out" warning light.

That little plastic welder has come in surprisingly handy.
 
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