This procedure covers removal and replacement of the headlight assembly on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine, including electrical connector removal and beam adjustment.

Warnings

Tools required

Parts

• Headlight assembly (driver or passenger side) × 1 — Specify halogen or HID version as equipped
• Push-pin retainers × 3 — Use OEM specification

Preparation

1. Park vehicle on level surface and turn off ignition
2. Open hood and secure with prop rod
3. Allow headlight assemblies to cool if vehicle was recently operated
4. Disconnect negative battery terminal and wait 2 minutes to allow capacitor discharge on HID-equipped models

Procedure

1. 1

   Remove grille upper cover panel
   Locate the plastic grille upper cover panel that spans across the top of the grille opening. Remove the push-pin retainers along the top edge (typically 6-8 retainers). Carefully pull the panel upward and away from the vehicle to access the headlight mounting bolts. Set panel aside in a clean area.
2. 2

   Disconnect headlight electrical connectors
   Reach behind the headlight assembly and locate the main headlight connector(s). For halogen models, there will be one main connector and one for the parking light. For HID models, locate the ballast connector and bulb connector. Press the release tab on each connector and pull straight back to disconnect. Do not pull on wires. If equipped with daytime running light module, disconnect that connector as well.
3. 3

   Remove upper headlight mounting bolts
   Using a 10mm socket and extension, remove the two upper headlight assembly mounting bolts accessible from the top of the grille opening. These bolts secure the top edge of the headlight assembly to the radiator support. Keep bolts organized for reinstallation.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
4. 4

   Remove lower headlight mounting bolt
   Locate the lower headlight mounting bolt near the bottom outer corner of the headlight assembly. This bolt may be accessed from above or through the wheel well area depending on clearance. Use a 10mm socket with extension to remove this bolt. On some models, partial wheel turn may improve access.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
5. 5

   Release headlight assembly from clips
   The headlight assembly is secured by mounting bolts and plastic alignment clips. Gently pull the headlight assembly straight forward and outward from the fender. You may need to wiggle it slightly to disengage the alignment pins from their grommets in the body panel. The assembly should come free with moderate pulling force.
6. 6

   Remove headlight assembly
   Once all mounting points are free, carefully remove the headlight assembly from the vehicle. Keep the assembly face-down on a clean towel or soft surface to prevent lens damage. Inspect the mounting points and alignment pins for damage.
7. 7

   Transfer components if necessary
   If installing a new headlight assembly, transfer any reusable components from the old assembly. This may include bulbs (if serviceable and in good condition), ballasts on HID models, or adjustment hardware. Ensure all bulbs are properly seated in the new assembly and avoid touching halogen or HID bulb glass with bare hands.
8. 8

   Install new headlight assembly
   Position the new headlight assembly into the mounting location, aligning the plastic locating pins with their grommets in the body panel. Press firmly to ensure the alignment pins are fully seated. The assembly should sit flush against the fender and grille opening with even gaps.
9. 9

   Install headlight mounting bolts
   Install the lower mounting bolt first, threading it by hand to ensure proper alignment. Then install the two upper mounting bolts. Tighten all three bolts to specification using a torque wrench in a cross pattern (upper left, lower, upper right) to ensure even seating of the assembly.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
10. 10

    Reconnect electrical connectors
    Reconnect all electrical connectors to the headlight assembly, ensuring each connector clicks firmly into place. Verify that connector locking tabs are fully engaged. Route wiring away from any sharp edges or heat sources. For HID models, ensure ballast connectors are secure and ballast is properly mounted.
11. 11

    Reinstall grille upper cover panel
    Position the grille upper cover panel back into place, aligning all mounting points. Press firmly on each push-pin retainer location until retainers click into place. Verify the panel is secure and sits flush with surrounding trim.
12. 12

    Reconnect battery and test operation
    Reconnect the negative battery terminal. Turn on the headlights and verify both low beam and high beam operation. Test turn signals and parking lights. Check for any error messages on the instrument cluster. On HID-equipped models, allow 10-15 seconds for full bulb warm-up.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure headlight assembly gaps are even and consistent with opposite side
3. Check that all grille cover panel retainers are properly installed
4. Verify no tools or fasteners were left in engine compartment

Verification

• Test low beam, high beam, turn signal, and parking light function on replaced headlight
• Verify headlight beam pattern illuminates the road properly without excessive scatter
• Check for moisture inside headlight lens (indicates improper seal)
• Perform headlight aim adjustment if beam pattern is not aligned with opposite side - adjust aim screws to manufacturer specifications using wall or headlight aiming equipment at 25 feet
• Verify no warning lights are illuminated on instrument cluster related to lighting system

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