This procedure covers the removal and replacement of the LED headlight module on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• LED headlight module assembly × 1 — Use OEM Ford specification for proper fitment and beam pattern
• Headlight bulb retaining clip × 1 — Replace if damaged during removal

Preparation

1. Park vehicle on level surface and turn off ignition
2. Allow headlights to cool completely if recently operated
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait 2 minutes for electrical system discharge

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the cable from the battery post and secure it away from the battery to prevent accidental reconnection during the repair.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove radiator cover panel
   Remove the plastic radiator cover panel that spans across the top of the grille area. Release the push-pin clips and remove any retaining screws securing the panel. Lift the panel upward and away to access the headlight assembly.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
3. 3

   Disconnect headlight electrical connector
   Locate the main electrical connector on the back of the headlight assembly. Press the locking tab and pull the connector straight out. Note the connector orientation for reassembly. If equipped with daytime running light or turn signal connectors, disconnect those as well.
4. 4

   Remove headlight assembly mounting bolts
   Locate the two or three headlight assembly mounting bolts accessible from the top of the engine bay. On 2011-2014 F-150s, these are typically 10mm bolts. Remove all mounting bolts while supporting the headlight assembly to prevent it from falling.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
5. 5

   Release lower headlight retaining tab
   Reach down behind the bumper cover to locate the lower headlight retaining tab. This plastic tab clips into a slot on the bottom of the headlight. Gently pry or push the tab to release it while pulling the headlight assembly forward slightly.
6. 6

   Remove headlight assembly
   With all fasteners removed and electrical connections disconnected, carefully pull the headlight assembly straight forward out of the mounting location. Maneuver it around any obstructions and remove it from the vehicle. Place on a clean, protected work surface.
7. 7

   Remove LED module from housing
   On the rear of the headlight assembly, locate the LED module mounting bolts or retaining clips. Remove the module mounting bolts using an 8mm socket. Carefully separate the LED module from the headlight housing, being careful not to touch the optical surfaces or LED array.
   ⚠Handle LED module only by the mounting tabs - fingerprints on LED arrays or reflectors will cause uneven beam patterns
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Install new LED module
   Position the new LED module into the headlight housing, ensuring the alignment pins are properly seated. Install the module mounting bolts and torque to specification. Verify the module is seated flush with no gaps.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Reinstall headlight assembly
   Position the headlight assembly back into the vehicle, aligning it with the mounting holes and lower retaining tab slot. Press firmly to engage the lower tab, then install the upper mounting bolts finger-tight before torquing to specification.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Reconnect electrical connectors
    Reconnect all headlight electrical connectors, ensuring they click firmly into place. Verify the locking tabs are fully engaged. Clean any corrosion from connector terminals if present using electrical contact cleaner.
11. 11

    Reinstall radiator cover panel
    Position the radiator cover panel back in place and secure with all push-pin clips and screws. Ensure all clips are fully seated and the panel is flush with surrounding components.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
12. 12

    Reconnect battery
    Reconnect the negative battery terminal to the battery post. Torque the terminal bolt to specification, being careful not to overtighten as this can damage the battery post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked before testing
2. Verify headlight assembly is properly aligned and flush with fender and grille before final torque
3. Check that no tools or parts were left in the engine compartment

Verification

• Turn ignition to ON position and activate headlights to verify LED module operates correctly
• Test low beam, high beam, and daytime running light functions if equipped
• Verify proper beam pattern on a wall or garage door - beam should have clear cutoff and proper spread
• Check for any warning lights on the instrument cluster related to lighting systems
• Ensure headlight assembly is secure with no rattles or movement when gently pushed

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