This procedure covers the removal and replacement of the headlight assembly on a 2011-2014 Ford F-150 with 5.0L V8 engine, including proper electrical connector removal and torque specifications.

Warnings

Tools required

Parts

• Headlight assembly (driver or passenger side) × 1 — Use OEM specification
• Retaining clip (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off ignition and remove key from vehicle
3. Allow engine to cool if recently operated
4. Open and secure hood in raised position

Procedure

1. 1

   Access headlight assembly
   Identify the headlight assembly to be replaced. From the engine bay, locate the rear of the headlight assembly behind the grille area. You will see the back of the headlight housing with electrical connectors attached.
2. 2

   Disconnect electrical connectors
   Locate the three electrical connectors on the back of the headlight assembly: low beam bulb connector, high beam bulb connector, and side marker/turn signal connector. Press the release tab on each connector and pull straight back to disconnect. If connectors are tight, gently wiggle while pulling. Note the position of each connector for reassembly.
   ⚠Do not pull on wiring harness; pull only on connector body to avoid damaging wires
3. 3

   Remove headlight assembly bolts
   Locate the two 10mm headlight assembly mounting bolts. One bolt is positioned at the top of the assembly near the radiator support, and one is located on the outboard side near the fender. Using a 10mm socket, remove both mounting bolts completely and set aside.
4. 4

   Release headlight assembly from clips
   With bolts removed, grasp the headlight assembly firmly with both hands. Pull the assembly straight forward away from the vehicle. The assembly is held by two lower retaining clips that will release as you pull. Apply steady, even pressure until the assembly comes free. Do not twist or bend the assembly during removal.
   ⚠Support the weight of the assembly to prevent it from falling and breaking once clips release
5. 5

   Inspect mounting points and clean area
   With the old headlight removed, inspect the mounting bracket and alignment pins on the vehicle for damage or corrosion. Check the lower retaining clips for proper function. Clean any debris, dirt, or corrosion from the mounting surface using a clean rag. Verify that alignment pins are straight and not bent.
6. 6

   Install new headlight assembly
   Position the new headlight assembly so the two lower clips align with their receptacles on the vehicle frame. The alignment pins on the vehicle should line up with holes in the back of the headlight housing. Push the assembly rearward until the lower clips engage with an audible click and the mounting bolt holes align.
7. 7

   Install and torque mounting bolts
   Insert both 10mm headlight assembly mounting bolts by hand, starting with the top bolt near the radiator support, then the outboard bolt near the fender. Thread both bolts in by hand to ensure proper alignment. Using a torque wrench and 10mm socket, tighten both bolts to specification in a cross pattern (top first, then outboard).
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
8. 8

   Reconnect electrical connectors
   Reconnect the three electrical connectors to their corresponding sockets on the back of the new headlight assembly. Match each connector to its socket: low beam bulb, high beam bulb, and side marker/turn signal. Push each connector firmly until you hear and feel a positive click, indicating the locking tab has engaged.
9. 9

   Test headlight operation
   Turn the ignition to the ON position (engine does not need to start). Test low beam, high beam, turn signal, and side marker functions for the newly installed headlight assembly. Verify all functions operate correctly before closing hood.
   ℹ️If any function does not work, verify electrical connectors are fully seated and locked

Reassembly

1. Verify all electrical connectors are fully seated and locked in place
2. Confirm both mounting bolts are torqued to specification
3. Ensure headlight assembly is flush with surrounding body panels and grille

Verification

• Turn on headlights and verify both low and high beams illuminate properly
• Activate turn signals and verify proper operation and flash rate
• Check headlight assembly alignment with opposite side for symmetry
• Inspect for any gaps between headlight assembly and adjacent body panels
• Verify no warning lights appear on instrument cluster related to lighting system
• Test headlight aim and adjust if necessary using adjuster screws at 3.0 Nm

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