Installing Hella 500s Behind the Grill

The Dodge Ram 5.7L HEMI© has a good amount of room between the radiators and the grill. It also has two very conveniently located cross members which make a great mounting point for behind the grill off-road lighting. This is a pretty easy mod, and the Hella 500 lighting kit I received has very nicely done installation instructions. I ended up wiring mine a bit different though because I wanted it to be a completely independent setup. The downside to having it completely independent is that I could forget to turn them off and kill the battery overnight.

One thing you have to remember about doing behind the grill lighting is that the grill design (especially the 2005 PW honeycomb design) isn't conducive to flood or fog lighting because it doesn't allow much lateral light escape. This means the lights you choose need to be driving lights / pencil or spot beams.

I didn't have a big enough deepwell socket to get the lights torqued down properly so the alignment is off. Once I get the right socket, I will not have both lights converging exactly on the same spot, but maybe a couple to four feet apart. The lights were also pointed down a little, so I need to raise them a bit.

For two 55w lights, they do pretty good. Getting on a back road with no traffic it really lights the distance up quite a bit.

Click on a picture for a larger, higher resolution view.

Same, but no flash

Got the ground (blue) and relay power

Nice long wires for easy routing and install

Wiring done, they're on

Low-beams and Hellas on single point

Lights off with hood closed

With the hood opened

Low-beams, fogs, Hellas on (with flash)

High-beams and Hellas on single point

Drilled two holes 12" from centerline

Another angle

Probably the only time these lights will have covers

Head on (some alignment) no fogs

Using the hood latch to center from

A little black Rustoleum paint

Here's the grill before


Head on no fogs

Temporarily wired switch

LED lights up when on

Here's what's in the kit

Another angle with them on

Quick check to make sure they're even

No LED light when off

Head on

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There are 9 comments so far.

September 24, 2008, 10:15 am (MST) - Kaleb said:
Where can I buy this exact kit you have?

March 24, 2009, 5:24 pm (MST) - adam said:
where did you tie in all the wires at? i got all the wires except the green wire with the fuse on it. they say to hook it up to the headlights but i wanted mine to work without the headlights. any help would be great.

October 13, 2009, 4:31 am (MST) - kish said:
Great mod. Do the lights let off enuff heat to damage the grille?? Thanks, Kish

December 6, 2010, 9:59 am (MST) - Jena said:
Hi, I am wanting to get my husband the same kit for his 2004 Dodge Ram. Do you know if the Hella 500 would work for his truck? Also, have you been happy with the Hella 500s or should I look at another brand? Any other information I should know about fog lights behind the grille? Thanks!

July 24, 2011, 2:27 pm (MST) - Brandon said:
I followed your same directions and added two lights behind the grill on my dodge ram just like you did. But the lights I bought didn't come with any wiring or anything. I want to wire the lights with a switch. Now I know absolutely nothing about wiring yet because im still young. Could you help me figure out how to wire my lights to a switch please??

September 10, 2012, 10:15 pm (MST) - Anonymous said:
Your answer shows real intelliegnce.

August 13, 2013, 4:07 am (MST) - echo law said:
Hello manager, This is echo from 360AUTOTEK, guangzhou, China. we are a factory mainy on manufacturing Aftermarket parts, exporting to all over the world. Recently we launch some new products for optimizing the market both my company and our customersï¼ they are LED working light, Halogen bulbs, Bi-xenon Lens, Carbon fibre vinyl, Parking sensor. Our slogan is where need us, we'll be where. Our company culture mainly enbody these: Passion, Faith, Self-confidence. SKYPE: uavtoteko7 TEL: 862084548396 WEB:

November 23, 2013, 3:57 am (MST) - Mark said:
Looks cool! I'm in the process of building a woven mesh grille to replace the existing grille on my Sprinter 4X4 to mount the lights behind. It will let out more light than the factory setup and will hinge down for cleaning the lenses and changing bulbs etc. Does the back of the lamps get too hot? Have you noticed the bulbs burning up too quickly?

November 11, 2015, 5:54 pm (MST) - ZvhJ6DxWlDz said:
I too am enjoying doing the mini alumbs. Both of mine are to be given as gifts to dear ones. I love making double page layouts too--mostly because I can get more pictures on a 12 x 12 page. I am so enjoying the format for this class because I can work on it at home within my own time frame. I am learning lots of wonderful new techniques, as well as lots of fun, better ways to use the BoBunny products. :-) Kris, I am glad you are enjoying doing this because it is a blessing for the rest of us. Please keep it up.


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