HELLA Sealed-Beam Conversion Headlights: Size & Bulb Guide

Older trucks, vans, RV chassis and classic vehicles may use a round or rectangular sealed-beam headlight. A HELLA replacement conversion can provide a serviceable halogen lamp, but diameter, reflector design, bulb family and approval markings all matter. Compare the exact MPN before choosing by appearance alone.

First identify the old sealed-beam format

Measure the existing light assembly and check the original sealed-beam designation. The products below cover 7-in round, 5¾-in round and nominal 7 × 6-in rectangular housings. They do not share a single mounting ring or bulb configuration.

A 5¾-in conversion may belong to a four-lamp headlight system, where separate high-beam and high/low-beam units are fitted. A 7-in round conversion commonly serves a different housing. Check the actual beam function rather than assuming all round lamps are dual-beam.

Exact HELLA part-number comparison

Bulb types, quantities and included components

H4 and 9003/HB2 refer to related dual-filament halogen headlight arrangements, but connector wiring, legal markings and the complete lamp kit must still be matched. The conversion assembly determines the correct replacement bulb and electrical arrangement.

The catalog lists 002395301, 002850811 and 003427291 as single conversion lamps. 002395801 is described as a two-lamp kit. Check the actual package for supplied bulbs, boots, adapters and other hardware; a lens-and-reflector listing does not necessarily include all wiring pieces.

Before replacing an RV or truck headlamp

1. Identify whether the factory lamp is 7-in round, 5¾-in round or rectangular, and measure the actual housing and retaining ring.
2. Check whether the old lamp is high-beam-only or dual high/low beam. Match that function and the original electrical connector.
3. Compare the precise HELLA MPN with its bulb specification, package contents, and manufacturer-approved application.
4. Confirm the new assembly has the necessary road-use certification for your jurisdiction, if it will be used on public roads.
5. After installation, aim the headlamps to the vehicle manufacturer's procedure; incorrect alignment can reduce visibility or cause glare.

Common questions

Can I install a 7-in round light where a 5¾-in lamp was fitted? No. These are different mounting formats with different retaining rings and often different beam arrangements.

Is a two-lamp kit the same as one replacement headlamp? No. Check quantity carefully when replacing both sides or only one damaged unit.

Does a 9003/HB2 bulb make any conversion road legal? No. Legal status depends on the complete headlamp assembly, optical design and approval markings, as well as applicable local requirements.

Compare five HELLA conversion listings

These cards link to exact store products. Check their availability, condition and components on the individual listing. The product photos are catalog references and do not establish the condition of an individual item.

HELLA 002395031 · 7-in round

H4 bulb family; 60W high / 55W low. Manufacturer's H4 lens and reflector conversion; check included bulbs for the actual package.

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HELLA 002395301 · 7-in round

9003/HB2 bulb family; 60W high / 55W low. Single Vision Plus conversion unit; manufacturer catalog uses the SAE/DOT description for this 7-in variant.

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HELLA 002395801 · 7-in round

H4 bulb family; 60W high / 55W low. Two-lamp kit in store listing. Confirm included bulbs, harness fittings and applicable approval markings.

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HELLA 002850811 · 5¾-in round

H4 bulb family; 60W high / 55W low. Single high/low-beam conversion lamp for the smaller round sealed-beam format; not a 7-in unit.

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HELLA 003427291 · 190 × 132 mm rectangular

9003/HB2 bulb family; 60W high / 55W low. Single rectangular headlamp conversion with a bulb and dust cover listed; nominal 7 × 6-in sealed-beam format.

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Other headlight parts and identification

If replacing only a failed bulb rather than the complete reflector assembly, use our HELLA H1, H2, H3 and R2 bulb-identification guide to compare base styles, voltages and power ratings before ordering. That guide is not a substitute for matching the complete headlamp assembly.