This procedure covers the removal and replacement of both left and right headlight assemblies on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including disconnection of electrical connectors and mounting hardware.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification or aftermarket equivalent
• Right headlight assembly × 1 — Use OEM specification or aftermarket equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all lights and accessories
3. Allow engine and headlights to cool for at least 30 minutes if recently operated
4. Open hood and secure in raised position
5. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge

Procedure

1. 1

   Access driver side headlight assembly
   From the engine bay, locate the driver side headlight assembly behind the grille area. You may need to remove or reposition the air intake duct slightly for better access on the driver side. Identify the two 10mm mounting bolts on top of the headlight assembly.
2. 2

   Disconnect driver side electrical connectors
   Locate the main headlight connector and any additional connectors for DRL, turn signal, or side marker lights at the rear of the assembly. Press the release tab on each connector and pull straight back to disconnect. If equipped with adaptive headlights, disconnect the motor connector as well.
3. 3

   Remove driver side headlight mounting bolts
   Remove the two 10mm mounting bolts from the top of the driver side headlight assembly. Gently pull the headlight assembly forward and outward from the mounting location. You may need to wiggle it slightly to disengage the lower mounting tab and alignment pins. Carefully remove the assembly from the vehicle.
4. 4

   Access passenger side headlight assembly
   Move to the passenger side of the vehicle. From the engine bay, locate the passenger side headlight assembly. Access is typically easier on this side. Identify the two 10mm mounting bolts on top of the headlight assembly.
5. 5

   Disconnect passenger side electrical connectors
   Locate all electrical connectors at the rear of the passenger side headlight assembly. Press the release tab on each connector and pull straight back to disconnect. Ensure all connectors are completely disconnected before proceeding.
6. 6

   Remove passenger side headlight mounting bolts
   Remove the two 10mm mounting bolts from the top of the passenger side headlight assembly. Gently pull the headlight assembly forward and outward, disengaging the lower mounting tab and alignment pins. Carefully remove the assembly from the vehicle.
7. 7

   Prepare new driver side headlight assembly
   Remove the new driver side headlight assembly from packaging. Inspect for any shipping damage. Verify that all mounting tabs and alignment pins are intact. Transfer any bulbs or components from the old assembly if the new assembly does not include them.
8. 8

   Install driver side headlight assembly
   Position the new driver side headlight assembly, aligning the lower mounting tab and alignment pins with their receptacles in the body. Push the assembly rearward until it seats flush against the mounting surface. Verify proper alignment with surrounding body panels and grille before securing.
9. 9

   Secure driver side headlight and connect electricals
   Install the two 10mm mounting bolts finger-tight, then tighten securely but do not overtighten to avoid cracking the mounting tabs. Reconnect all electrical connectors, ensuring each clicks into place and is fully seated. Verify connectors match their original positions.
10. 10

    Prepare new passenger side headlight assembly
    Remove the new passenger side headlight assembly from packaging and inspect for damage. Verify mounting tabs and alignment pins are intact. Transfer any necessary bulbs or components from the old assembly if not included with the new unit.
11. 11

    Install passenger side headlight assembly
    Position the new passenger side headlight assembly, aligning the lower mounting tab and alignment pins with the body receptacles. Push the assembly rearward until fully seated and flush with the mounting surface. Check alignment with body panels and grille.
12. 12

    Secure passenger side headlight and connect electricals
    Install the two 10mm mounting bolts finger-tight, then tighten securely without overtightening. Reconnect all electrical connectors at the rear of the assembly, ensuring each connector clicks and seats properly. Double-check all connections are secure.
13. 13

    Reconnect battery and test operation
    Reconnect the negative battery terminal. Turn the ignition to the ON position without starting the engine. Test low beams, high beams, turn signals, and DRLs on both sides. Verify all functions operate correctly. Check for proper beam pattern alignment.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Reposition any air intake ducts or components that were moved for access
2. Verify all electrical connectors are fully seated and secured
3. Check that headlight assemblies are flush with body panels and grille with no gaps
4. Ensure hood closes properly without interference from headlight assemblies

Verification

• Perform complete headlight function test including low beam, high beam, DRL, and turn signals on both sides
• Visually inspect headlight alignment and verify beam patterns are level and properly aimed
• Check for proper fitment with no gaps between headlight assemblies and body panels
• Verify no warning lights or error messages appear on the instrument cluster
• Test-drive vehicle in dark conditions to confirm adequate illumination and proper operation

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