This procedure covers the replacement of a failed HID ballast on a 2011-2014 Ford F-150 with factory HID headlights, including accessing the headlight assembly and proper electrical connections.

Warnings

Tools required

Parts

• HID ballast assembly × 1 — Use OEM Ford or quality aftermarket (Philips, Hella, Osram)
• Push pin retainers (if damaged) × 3 — Ford W710483-S439

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off headlights and ignition
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait minimum 2 minutes for HID system capacitor discharge
5. Identify which ballast has failed (driver or passenger side)
6. Allow headlight assembly to cool if vehicle was recently driven

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the cable from the terminal and secure away from battery post 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 (if equipped) by removing push pin retainers along the top edge. Pull panel upward and toward engine to release from lower clips. Set aside with retainers.
3. 3

   Access headlight assembly area
   Locate the headlight assembly on the affected side. On the F-150, the HID ballast is mounted to the back of the headlight assembly or on the inner fender well. You do not need to remove the entire headlight assembly for ballast replacement.
4. 4

   Locate and identify HID ballast
   Identify the HID ballast, which is a rectangular metal or plastic module connected to the back of the HID bulb via a high-voltage cable. Trace the wiring from the bulb to confirm you have located the correct ballast. Note the orientation and routing of all connectors.
5. 5

   Disconnect ballast electrical connectors
   Press the release tab on the main power connector and pull straight back to disconnect from the ballast. Disconnect the high-voltage connector leading to the HID bulb by releasing the locking clip. Handle the high-voltage connector carefully and avoid pulling on wires.
   ⚠Even with battery disconnected, residual voltage may be present. Do not touch exposed metal contacts.
6. 6

   Remove ballast mounting hardware
   Remove the ballast mounting bolts using an 8mm socket. Most F-150 HID ballasts use two or three mounting bolts. Support the ballast with your hand while removing the final bolt to prevent it from falling.
   Torque spec

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

   Remove failed ballast
   Carefully withdraw the ballast from its mounting location. Thread the connectors and wiring through any clips or brackets. Inspect the mounting surface for corrosion or damage. Clean mounting surface with a shop towel if needed.
8. 8

   Prepare new ballast for installation
   Remove new ballast from packaging. Compare with old ballast to verify correct part. Check that all mounting holes align and connectors match. If using dielectric grease, apply a small amount to the inside of the power connector (not the high-voltage connector).
9. 9

   Install new ballast
   Position the new ballast in the mounting location with the same orientation as the original. Thread wiring through any clips or brackets. Align mounting holes and hand-thread mounting bolts to prevent cross-threading.
10. 10

    Torque ballast mounting bolts
    Using a torque wrench with 8mm socket, tighten the ballast mounting bolts in a cross pattern (if multiple bolts) to the specified torque. Ensure ballast is seated firmly against mounting surface before final torquing.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect ballast electrical connectors
    Connect the high-voltage connector to the HID bulb first, ensuring the locking clip fully engages with an audible click. Then connect the main power connector to the ballast, pressing until you hear/feel it click into place. Gently tug on both connectors to verify they are fully seated.
12. 12

    Secure wiring and reinstall covers
    Route all wiring through original clips and secure to prevent contact with moving parts or hot surfaces. Reinstall the radiator cover panel by aligning lower clips first, then pressing down on top edge while installing push pin retainers.
13. 13

    Reconnect battery
    Reconnect the negative battery terminal to the battery post. Torque the terminal bolt to specification using a 10mm socket and torque wrench. Ensure terminal has good contact with battery post.
    ℹ️Do not overtighten battery terminal bolt as this can damage the terminal or battery post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all wiring is routed away from hot or moving components
3. Confirm ballast mounting bolts are torqued to specification
4. Check that no tools or parts were left in engine bay

Verification

• Turn ignition to ON position without starting engine and activate headlights
• Verify both headlights illuminate properly (HID bulbs may flicker briefly during warm-up)
• Check that both low and high beam functions operate correctly
• Observe headlight operation for 2-3 minutes to ensure no flickering or shutdown occurs
• Verify no warning lights appear on instrument cluster
• Visually inspect for proper light output and color temperature matching between headlights
• Close hood and verify all covers and panels are properly secured

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