This procedure covers the replacement of a single headlight bulb on a 2011-2014 Ford F-150 with the 3.5L EcoBoost engine, requiring removal of the headlight assembly for bulb access.

Warnings

Tools required

Parts

• H11 headlight bulb (low beam) or 9005 bulb (high beam) × 1 — Verify bulb type for your specific application

Preparation

1. Park vehicle on level surface and turn off ignition
2. Allow headlight assembly to cool completely if recently operated
3. Open hood and secure with prop rod
4. Put on nitrile gloves to prevent skin oils from contacting new bulb

Procedure

1. 1

   Access headlight assembly mounting bolts
   Locate the two headlight assembly mounting bolts on top of the headlight housing. These are positioned along the upper edge of the assembly, accessible from the engine bay.
2. 2

   Remove upper mounting bolts
   Using an 8mm socket with 3-inch extension and ratchet, remove the two upper mounting bolts securing the headlight assembly to the radiator support. Store bolts in a safe location.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
3. 3

   Release lower retaining clip
   Reach behind the lower portion of the headlight assembly and locate the spring-loaded retaining clip. Push the clip inward toward the center of the vehicle while pulling the assembly forward slightly to disengage.
4. 4

   Pull headlight assembly forward
   Carefully pull the headlight assembly straight forward away from the vehicle body approximately 3-4 inches. Do not fully remove yet as wiring harnesses are still connected.
5. 5

   Disconnect wiring harnesses
   Locate the wiring connector(s) on the back of the headlight assembly. Press the release tab and pull the connector straight out. There may be separate connectors for low beam, high beam, and parking light depending on bulb being replaced.
6. 6

   Remove headlight assembly
   With all electrical connections disconnected, fully remove the headlight assembly from the vehicle and place on a clean work surface with the rear of the assembly facing up.
7. 7

   Remove bulb dust cover
   Locate the rubber or plastic dust cover on the back of the headlight assembly corresponding to the bulb being replaced. Twist counterclockwise approximately 1/4 turn and pull straight out to remove.
8. 8

   Release bulb retaining ring
   Locate the wire retaining ring that secures the bulb. Press down on the ring and rotate counterclockwise to release, then swing the ring out of the way to access the bulb.
   Torque spec

   Bulb Retaining Ring5 Nm (4 lb-ft)
9. 9

   Remove failed bulb
   Grasp the bulb base (not the glass) and pull straight out from the reflector housing. Dispose of old bulb properly. Inspect the socket for any corrosion or damage.
10. 10

    Install new bulb
    Remove new bulb from packaging by handling only the plastic base. Align the bulb tabs with the slots in the socket and push straight in until fully seated. Ensure bulb is properly oriented with the tab positions.
11. 11

    Secure bulb retaining ring
    Swing the wire retaining ring back over the bulb base and rotate clockwise to lock in position. Verify the ring is fully engaged and holding the bulb securely against the housing.
    Torque spec

    Bulb Retaining Ring5 Nm (4 lb-ft)
12. 12

    Reinstall dust cover
    Align the dust cover with the opening on the back of the headlight assembly. Push in firmly and rotate clockwise approximately 1/4 turn until it locks into place. Ensure a complete seal to prevent moisture entry.
13. 13

    Reconnect wiring harnesses
    Reconnect all electrical connectors to the back of the headlight assembly. Push firmly until you hear or feel a click indicating proper engagement.
14. 14

    Reinstall headlight assembly
    Position the headlight assembly into the vehicle opening. Align the lower retaining clip first and push in until it clicks into place, then align the upper mounting bolt holes with the radiator support.
15. 15

    Install mounting bolts
    Install the two upper mounting bolts and hand-tighten. Using the 8mm socket with extension and ratchet, torque the mounting bolts to specification in a cross pattern to ensure even seating.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

Reassembly

1. Verify headlight assembly is flush with surrounding body panels and properly aligned
2. Ensure all electrical connectors are fully seated and locked
3. Confirm dust cover is properly sealed to prevent moisture intrusion

Verification

• Turn ignition to ON position without starting engine
• Test low beam function by turning on headlights
• Test high beam function using high beam switch
• Verify no warning lights are illuminated on instrument cluster
• Visually inspect headlight operation from outside vehicle to confirm proper beam pattern and bulb operation
• Check for any light leaks around headlight assembly perimeter that would indicate improper seating

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