This procedure covers the removal and replacement of both headlight assemblies on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine, including electrical connector disconnection and proper alignment.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification or aftermarket equivalent
• Right headlight assembly × 1 — Use OEM specification or aftermarket equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently driven
3. Open hood and secure with prop rod
4. Disconnect battery negative terminal and wait 2 minutes for airbag system capacitor discharge
5. Gather all tools and new headlight assemblies

Procedure

1. 1

   Remove driver side radiator cover panel
   Locate the radiator cover panel above the driver side headlight. Remove the plastic push pins and retaining clips securing the cover panel. Lift the panel upward and away from the radiator support to access the headlight mounting bolts.
2. 2

   Disconnect driver side headlight electrical connectors
   Locate the three electrical connectors on the rear of the driver side headlight assembly: main headlight connector, parking light connector, and turn signal connector. Press the locking tabs and pull each connector straight back from the bulb sockets. For HID-equipped vehicles, also disconnect the ballast connector.
3. 3

   Remove driver side headlight mounting bolts
   Locate the two 10mm mounting bolts at the top of the headlight assembly along the radiator support. Remove both bolts completely. The headlight assembly is now secured only by the lower alignment tab.
4. 4

   Remove driver side headlight assembly
   Carefully pull the headlight assembly forward and upward to disengage the lower alignment tab from the fender bracket. Tilt the assembly outward from the top to clear the fender and remove it completely from the vehicle. Inspect the mounting points for damage or corrosion.
5. 5

   Install new driver side headlight assembly
   Position the new headlight assembly near the opening. Align the lower tab with the fender bracket slot and insert it first. Rotate the assembly into position, ensuring all alignment tabs engage properly with the fender and radiator support. The assembly should sit flush with surrounding panels.
6. 6

   Install driver side headlight mounting bolts
   Insert both 10mm mounting bolts through the headlight assembly into the radiator support. Hand-thread both bolts first to ensure proper alignment, then tighten to specification using a torque wrench. Verify the headlight is seated evenly before final torque.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Reconnect driver side headlight electrical connectors
   Reconnect the three electrical connectors to the corresponding bulb sockets on the rear of the headlight assembly. Push each connector firmly until the locking tab clicks into place. Ensure each connection is secure with no gap between connector and socket.
8. 8

   Reinstall driver side radiator cover panel
   Position the radiator cover panel over the radiator support and headlight assembly. Press down firmly on each push pin location until you hear or feel them click into place. Verify all clips are fully seated.
9. 9

   Remove passenger side radiator cover panel
   Locate the radiator cover panel above the passenger side headlight. Remove the plastic push pins and retaining clips securing the cover panel. Lift the panel upward and away from the radiator support to access the headlight mounting bolts.
10. 10

    Disconnect passenger side headlight electrical connectors
    Locate the three electrical connectors on the rear of the passenger side headlight assembly: main headlight connector, parking light connector, and turn signal connector. Press the locking tabs and pull each connector straight back from the bulb sockets. For HID-equipped vehicles, also disconnect the ballast connector.
11. 11

    Remove passenger side headlight mounting bolts
    Locate the two 10mm mounting bolts at the top of the headlight assembly along the radiator support. Remove both bolts completely. The headlight assembly is now secured only by the lower alignment tab.
12. 12

    Remove passenger side headlight assembly
    Carefully pull the headlight assembly forward and upward to disengage the lower alignment tab from the fender bracket. Tilt the assembly outward from the top to clear the fender and remove it completely from the vehicle. Inspect the mounting points for damage or corrosion.
13. 13

    Install new passenger side headlight assembly
    Position the new headlight assembly near the opening. Align the lower tab with the fender bracket slot and insert it first. Rotate the assembly into position, ensuring all alignment tabs engage properly with the fender and radiator support. The assembly should sit flush with surrounding panels.
14. 14

    Install passenger side headlight mounting bolts
    Insert both 10mm mounting bolts through the headlight assembly into the radiator support. Hand-thread both bolts first to ensure proper alignment, then tighten to specification using a torque wrench. Verify the headlight is seated evenly before final torque.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
15. 15

    Reconnect passenger side headlight electrical connectors
    Reconnect the three electrical connectors to the corresponding bulb sockets on the rear of the headlight assembly. Push each connector firmly until the locking tab clicks into place. Ensure each connection is secure with no gap between connector and socket.
16. 16

    Reinstall passenger side radiator cover panel
    Position the radiator cover panel over the radiator support and headlight assembly. Press down firmly on each push pin location until you hear or feel them click into place. Verify all clips are fully seated.
17. 17

    Reconnect battery and test operation
    Reconnect the battery negative terminal and tighten to specification. Turn the ignition to the ON position without starting the engine. Test low beams, high beams, parking lights, and turn signals on both sides to verify all functions operate correctly.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify headlight assemblies are flush with fender and grille panels with no gaps
3. Confirm all radiator cover panels and push pins are properly installed
4. Check that headlight adjustment screws are accessible for future aim correction

Verification

• Turn ignition to ON position and verify both headlights illuminate on low beam
• Test high beam function on both headlights
• Verify parking lights and turn signals operate on both sides
• Inspect headlight alignment - both beams should point straight ahead initially
• Have headlight aim professionally adjusted or use proper alignment equipment to ensure correct beam pattern
• Check for any error messages or warning lights on the instrument cluster

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