Buy Chevrolet (Chevy) Express 3500 Headlight Assembly

Overview

Chevrolet Express 3500 headlights-also called headlamps, forward lamps, front lights, or head-light assemblies-are sealed-beam or composite units that handle both seeing and being seen. From 1996-2020 most vans use an H6054 (6052) sealed-beam for high and low beams; starting in some trims for 2017-2020, separate 9005 (high) and 9006 (low) replaceable-bulb housings appear. (AUXITO) Proper care, fuse protection, aiming, and legal upgrades all matter because headlights are key to safety and night-time visibility.

Fitment Years

• 1996-2016 - H6054 sealed-beam head-lamp fits cargo, passenger, and cut-away bodies.
• 2017-2020 - H6054 continues on many trims, but some receive composite housings that accept 9005/9006 bulbs.
• Check VIN and build sheet: shuttle, school-bus, or RV cut-aways sometimes keep the earlier sealed-beam even in later years.

Bulb Specs

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Data verified in GM owner manuals.

Fuses & Relays

The under-hood fuse block protects the circuit:

• Fuse 42 & 43 - low-beam left/right
• Fuse 44 & 45 - high-beam left/right
• Relay 58 - low-beam control
• Relay 56 - high-beam control (Fuse Box)

If both lamps quit, start with the matching fuse, then test the relay, then the multifunction (dimmer) switch.

Installation Tips

1. Open the hood and remove the two 10 mm bolts securing the head-light frame.
2. Pull the assembly forward; on sealed-beam versions unplug the three-pin connector.
3. For replaceable bulbs, twist the bulb socket counter-clockwise; avoid touching the quartz glass. Halogen oil spots shorten life.
4. Reverse steps to install, making sure the rubber boot seals out water.

A four-minute tutorial video shows the entire swap on a 2010 van.

Aiming Procedure

Express head-lamp housings allow vertical adjustment only; aim screws sit at the top-center of each lamp.

• Park 25 ft (7.6 m) from a flat wall.
• Mark lamp centers on the wall at the same height as lamp centers.
• Turn low beams on and rotate the screw until the top edge of the light pattern rests 2 in (5 cm) below the mark. This prevents glare.

Common Symptoms

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Upgrade Options

Modern 7×6 in LED projector units bolt directly into the sealed-beam frame, adding daytime-running halos and drawing ~45 W. (Auxbeam Lighting) They must carry the DOT marking to meet FMVSS 108.

• Legal note: NHTSA allows LEDs inside an integral beam lamp but not as plug-in replacements for 9005/9006 bulbs unless the assembly is certified.
• Look for an "SAE HR" or "DOT" mark molded into the lens before purchase.

Care & Maintenance

• Clean lenses with mild soap; avoid ammonia that clouds polycarbonate.
• Reseat the rear vent cap after service-vented housings clear normal moisture.
• Apply dielectric grease to the 3-pin connector to slow corrosion.
• Replace lamps in pairs; old bulbs fade 20-30 % over life.

Safety & Law

FMVSS 108 requires two steady-burning beams and a blue high-beam indicator on the dash. Commercial vans over 10 000 lb GVWR must retain DOT-marked lamps per § 393.24.

IIHS studies show vehicles with "good" headlights cut night crash rates by ~20 %. Keeping Express lamps bright-and correctly aimed-pays dividends in safety and liability.

Environmental Notes

Halogen sealed-beams contain glass, steel, and a small tungsten filament-fully recyclable as mixed metal/glass. LEDs last 30 000+ hrs and lower landfill waste but include circuit boards that require e-waste handling. Dispose lamps at local household-hazard centers.

Recycling & Disposal

1. Wear gloves; broken glass edges are sharp.
2. Drop halogen lamps at municipal recycling-check for "lamps & bulbs" bin.
3. For LED modules, ask the county e-waste program; boards include copper and rare-earth phosphors. Many cities accept them during "electronics roundup" events.

Troubleshooting Flow

1. Both beams out → check fuses 42-45, battery voltage, dimmer switch.
2. One side out → swap bulb side-to-side; if fault moves, bulb is bad.
3. Intermittent → inspect ground strap under left-hand radiator support.
4. Moisture → run lamps for an hour; if beads remain, replace the seal or the assembly.

Frequently Asked Questions

Q: What head-lamp bulb does a 2010 Express 3500 use?
A: It uses an H6054 sealed-beam for both high and low beams unless factory-upgraded to the composite 9005/9006 setup in later packages. (AUXITO)

Q: How long does a sealed-beam last?
A: Average life is 400-600 hours-about 5 years for typical van use-before brightness falls below 70 % of new.

Q: Can I convert to LEDs?
A: Yes, if the entire lamp assembly is DOT-marked and FMVSS 108-compliant. Simple plug-in LED "bulbs" are not legal for the Express's sealed-beam socket.

Q: My lamp fogs after a wash. Is that a defect?
A: A light white mist that clears within 6 hours is normal condensation. Large droplets or standing water means the seal is leaking and the lamp needs service.

Q: Where is the head-light fuse?
A: In the engine-bay fuse block: fuses 42-45 protect each beam; relays 56 and 58 switch high and low beams. (Fuse Box)

Q: How do I stop the head-lamp from vibrating?
A: Replace the missing tension spring behind the sealed-beam and snug the frame screws.

Q: Do I need special tools to change a bulb?
A: Only a 10 mm socket or nut driver. The job takes under 10 minutes.

Q: Why did both low beams quit but highs still work?
A: The low-beam relay (58) or its fuse likely failed; highs run on a separate circuit.

Q: Is it safe to touch the new halogen bulb?
A: No. Oil from fingers creates a hot spot and shortens lamp life. Handle by the base or wear gloves.

Q: Are brighter aftermarket bulbs legal?
A: They are legal if they meet DOT specs and do not exceed OE wattage; always look for "DOT" and "SAE HR" marks.

Key Takeaways

• Match the correct bulb type (H6054 or 9005/9006) to your build year.
• Use fuse-box chart to diagnose power loss quickly.
• Aim lamps vertically to prevent glare.
• Choose DOT-marked LED assemblies for legal upgrades.
• Clear condensation is normal; standing water is not.
  Regular inspections and timely replacements keep your Chevy Express 3500 shining bright and street-legal-helping you and everyone on the road stay safe.