This procedure covers the removal and replacement of the LED headlight module assembly on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• LED headlight module assembly × 1 — Use OEM Ford part number specific to driver or passenger side
• Headlight mounting hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all lights and remove key from ignition
3. Allow engine and headlight assemblies to cool for at least 30 minutes if recently operated
4. Open hood and secure with prop rod
5. Disconnect negative battery terminal and wait 2 minutes for system discharge

Procedure

1. 1

   Disconnect negative battery terminal
   Loosen the 10mm bolt on the negative battery terminal. Remove the cable from the terminal and secure it away from the battery post to prevent accidental reconnection during the repair.
   Torque spec

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

   Remove grille upper retaining clips
   Locate the plastic push-pin retainers along the top edge of the grille above the headlight assembly. Using a trim panel removal tool, carefully pry up the center portion of each clip, then remove the entire clip. Remove 3-4 clips in the area above the headlight being replaced.
3. 3

   Access headlight mounting area
   Pull the top edge of the grille forward slightly to create access to the headlight mounting bolts. The grille does not need to be completely removed for headlight access. If needed, remove the plastic radiator cover panel above the headlight by releasing its retaining clips.
4. 4

   Disconnect headlight electrical connectors
   Locate the main headlight wiring harness connector on the back of the headlight assembly. Press the release tab and pull the connector straight back from the headlight module. There may be 2-3 connectors depending on options (main headlight, DRL, and turn signal). Disconnect all connectors and note their positions for reassembly.
5. 5

   Remove headlight mounting bolts
   Locate the three 8mm headlight mounting bolts - typically one at the top, one on the inner side near the grille, and one on the outer side near the fender. Remove all three bolts completely and retain them for reinstallation.
   Torque spec

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

   Remove headlight assembly
   Carefully pull the headlight assembly forward and outward from the vehicle. The assembly may require gentle wiggling to release from alignment pins. Guide the assembly out of the headlight opening, being careful not to scratch the fender or bumper painted surfaces. Set the old assembly on a protected work surface.
7. 7

   Inspect mounting points and clean surfaces
   Inspect the headlight mounting bracket area for any damage, corrosion, or debris. Clean the mounting surfaces with a clean rag. Check the condition of the rubber seal/gasket around the headlight opening and replace if damaged. Verify all mounting bolt threads are clean and undamaged.
8. 8

   Prepare new LED headlight module
   Remove the new LED headlight module from its protective packaging. Inspect for any shipping damage. Do not touch the LED elements or lens surface with bare hands. Verify the part number matches the vehicle application and is correct for driver or passenger side. Transfer any necessary hardware from old assembly if not included with new module.
9. 9

   Install new headlight assembly
   Carefully align the new headlight assembly with the mounting bracket and alignment pins in the headlight opening. Push the assembly straight back into position, ensuring it seats fully against the mounting surface. The assembly should sit flush with no gaps around the perimeter.
10. 10

    Install headlight mounting bolts
    Start all three mounting bolts by hand to ensure proper thread engagement. Once all bolts are started, tighten them in a cross pattern using a torque wrench to 8.0 Nm (6.0 lb-ft). Verify the headlight assembly is properly seated and aligned with adjacent body panels.
    Torque spec

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

    Reconnect electrical connectors
    Reconnect all headlight electrical connectors in their original positions. Each connector should click audibly when fully seated. Gently tug on each connector to verify it is locked in place. Route wiring harnesses away from any sharp edges or heat sources.
12. 12

    Reinstall grille components
    Push the grille back into its normal position. Reinstall all plastic push-pin retainers that were removed, pressing them firmly until the center portion clicks and locks. If the radiator cover panel was removed, reinstall it and secure all retaining clips.
13. 13

    Reconnect battery
    Reconnect the negative battery cable to the negative terminal. Tighten the 10mm terminal bolt to 6.0 Nm (4.0 lb-ft). Do not overtighten as this can damage the battery post or terminal.
    ⚠Do not overtighten battery terminal bolt - excessive torque can crack battery post
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm headlight assembly is flush with body panels and properly aligned
3. Ensure all grille retaining clips are fully secured
4. Check that no tools or parts were left in engine compartment

Verification

• Turn ignition to ON position and verify headlight module powers on
• Test low beam function - verify proper illumination and aim
• Test high beam function - verify proper operation
• Test turn signal function if integrated into headlight assembly
• Test daytime running lights (DRL) if equipped
• Verify no warning lights on instrument cluster related to lighting systems
• Inspect headlight assembly from outside vehicle to confirm proper seating and alignment with body panels
• If headlight aim appears incorrect, perform headlight aiming procedure per Ford specifications

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