In support of the Department of Energy ( DOE) "SuperTruck" program, a group of low energy, high output light emitting diode (LED) lamps were developed for forward lighting. Reduction of the energy needs of the truck by saving fuel and reducing CO₂ emissions are two of the goals of this program. In support of the energy reduction, a retrofit LED headlamp was designed, built and tested. The retrofit headlamp was switched from a halogen bulb to an LED-based system. The LED headlamp requires a new approach in heat management. The use of the LED, which is a 2π source, requires a different strategy in the optics from those used with a 4π source, like a traditional incandescent, halogen, or High Intensity Discharge (HID) light source.A thermal management system is necessary to facilitate the long life of the LED source. A unique method for removing the heat of the LED and maintaining an acceptable temperature was tested and reported. The methods used in the design and testing are discussed along with measured data.