This procedure covers the removal and replacement of the LED headlight module assembly on the 2011-2014 Ford F-150 with 5.0L V8 Coyote engine.

Warnings

Tools required

Parts

• LED Headlight Module Assembly (Driver or Passenger side) × 1 — Use OEM Ford specification or equivalent aftermarket
• Push-pin retainers (if damaged during removal) × 5 — Ford N807389-S439

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition to OFF position and remove key
3. Allow engine and surrounding components to cool completely
4. Open hood and secure with hood prop
5. Disconnect negative battery terminal to prevent electrical shorts

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 terminal to prevent accidental reconnection during the procedure.
   Torque spec

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

   Access headlight module area
   Depending on which side you are replacing, turn the steering wheel fully to the opposite direction (replacing driver side, turn wheel fully right). This provides better access to the mounting bolts and connectors. Remove any upper radiator cover panels if they obstruct access to the headlight assembly mounting area.
3. 3

   Remove grille push-pin retainers
   Locate the push-pin retainers securing the upper grille section near the headlight assembly. Using a trim panel removal tool, carefully pry up the center portion of each push-pin, then remove the entire retainer. There are typically 3-4 retainers along the top edge of the grille section adjacent to the headlight.
   ⚠Push-pin retainers are fragile. Work carefully to avoid breaking the clips.
4. 4

   Disconnect headlight electrical connectors
   Reach behind the headlight assembly and locate the main headlight connector (large multi-pin connector). Press the release tab and pull the connector straight back to disconnect. Also disconnect any additional connectors for LED daytime running lights or side marker lights integrated into the assembly. Note the routing of the wiring harness for reassembly.
5. 5

   Remove upper headlight mounting bolts
   Locate the two upper mounting bolts securing the headlight assembly to the radiator support. These are typically 10mm bolts accessible from the top. Remove both bolts completely and set aside. Do not allow the headlight assembly to fall forward as lower bolts are still engaged.
   ⚠Support the headlight assembly with one hand as you remove the upper bolts to prevent it from tilting forward.
   Torque spec

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

   Remove lower headlight mounting bolt
   Working from above or reaching down from the wheel well area, locate the lower mounting bolt securing the bottom of the headlight assembly. This may require a 6-inch extension to reach. Remove the bolt completely. The headlight assembly is now free from the vehicle but still in position.
   Torque spec

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

   Remove headlight module assembly
   Carefully pull the headlight assembly forward and away from the vehicle. The assembly has alignment pins at the rear that fit into the radiator support - you may need to wiggle it slightly to disengage these pins. Once clear, remove the assembly completely and place it on a clean, protected work surface. Inspect the mounting points and alignment pins for damage.
8. 8

   Inspect and clean mounting surfaces
   With the old headlight removed, inspect the mounting bracket on the radiator support for damage, corrosion, or broken tabs. Clean any dirt or debris from the mounting surface and alignment pin holes using a shop towel. Check the condition of any rubber isolators or seals in the mounting points.
9. 9

   Install new LED headlight module
   Position the new headlight assembly near the mounting location. Align the rear locating pins with the holes in the radiator support. Carefully push the assembly straight back until it seats fully against the mounting surface. Verify that all alignment pins are properly engaged and the assembly sits flush with no gaps.
   ⚠Do not force the assembly. If it does not seat easily, remove and check for obstructions or misalignment.
10. 10

    Install lower mounting bolt
    Insert the lower mounting bolt and thread it by hand to ensure proper engagement. Using a torque wrench and appropriate socket with extension, tighten the lower bolt to specification. Verify the headlight assembly is properly seated before torquing.
    Torque spec

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

    Install upper mounting bolts
    Insert both upper mounting bolts and thread them by hand. Once both are started, use a torque wrench to tighten each bolt to specification in an alternating pattern (tighten one partially, then the other, then return to torque both to final spec). This ensures even seating of the assembly.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Reconnect electrical connectors
    Route the wiring harness as noted during disassembly. Connect the main headlight connector by pushing it firmly onto the module until you hear or feel a positive click. Connect any additional connectors for daytime running lights or side markers. Gently tug on each connector to verify it is fully seated and locked.
13. 13

    Reinstall grille retainers and panels
    Reinstall any grille push-pin retainers that were removed. Insert the retainer body into the hole, then press the center pin down until it is flush with the retainer body. Replace any damaged retainers with new ones. Reinstall any upper radiator cover panels that were removed.
14. 14

    Reconnect battery and test
    Reconnect the negative battery terminal and tighten the terminal bolt to specification. Turn the ignition to the ON position (engine off) and test all headlight functions: low beam, high beam, turn signal, and daytime running lights if equipped. Verify proper operation before closing the hood.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked in place
2. Verify headlight assembly is flush with surrounding body panels with no gaps
3. Check that all mounting bolts are torqued to specification
4. Replace any damaged push-pin retainers with new parts

Verification

• With ignition ON, verify low beam headlights illuminate properly on both sides
• Test high beam function and verify proper operation
• Check turn signal and side marker light operation
• Verify daytime running lights function if equipped
• Inspect headlight alignment - beam pattern should be level and not aimed too high or low (perform headlight aim adjustment if necessary)
• Check for any warning lights on the instrument cluster related to lighting systems
• Verify no gaps exist between headlight assembly and surrounding body panels

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