This procedure replaces a failed HID ballast on a 2015-2020 Ford F-150 equipped with factory HID headlights, restoring proper headlight operation.

Warnings

Tools required

Parts

• HID ballast assembly × 1 — Use OEM Ford specification or quality aftermarket (Philips, Hella, Osram)
• Dielectric grease packet × 1 — Small tube for connector protection

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off headlights and ignition, remove key from vehicle
3. Wait at least 5 minutes after last headlight use to allow HID capacitors to discharge
4. Open hood and secure with prop rod
5. Identify which ballast has failed (driver or passenger side) based on which headlight is not functioning
6. Put on gloves to protect from sharp edges and prevent contamination of components

Procedure

1. 1

   Remove radiator cover panel (if equipped)
   Some F-150 models have a plastic radiator sight shield that must be removed for access. If present, remove the plastic push clips along the top edge using trim removal tool and lift panel upward and out. Set aside.
2. 2

   Access headlight assembly area
   Locate the headlight assembly on the affected side. Remove the two plastic push pins securing the upper portion of the wheel well liner to the fender (if necessary for access). This may provide additional working room depending on which side you're working on.
3. 3

   Locate HID ballast
   The HID ballast is mounted to a bracket behind the headlight assembly, typically secured to the inner fender well or headlight mounting bracket. It is a rectangular metal box approximately 4x3 inches with a large wiring harness connector and a high-voltage connector going to the bulb. Visually confirm you have located the correct component.
4. 4

   Disconnect ballast electrical connectors
   Locate the main ballast power connector (large multi-pin connector). Press the locking tab and pull connector straight away from ballast. Then disconnect the high-voltage output connector that runs to the HID bulb by pressing its release tab and separating. Note connector orientation for reinstallation.
5. 5

   Remove ballast mounting hardware
   The ballast is typically secured with two or three mounting bolts or screws to a bracket. Using a 10mm socket or Torx T20 driver (depending on year and configuration), remove the mounting bolts securing the ballast to its bracket. Support the ballast as you remove the final fastener to prevent it from falling.
   Torque spec

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

   Remove failed ballast
   Carefully extract the failed ballast from its mounting location. You may need to maneuver it around other components. Inspect the mounting bracket for corrosion or damage. If bracket is corroded, clean with wire brush before installing new ballast.
7. 7

   Prepare new ballast for installation
   Remove new ballast from packaging. Verify it matches the failed unit in physical size, connector types, and mounting hole locations. Apply a small amount of dielectric grease to the connector terminals on both the power connector and high-voltage connector to prevent corrosion and ensure good contact.
8. 8

   Install new ballast
   Position the new ballast onto the mounting bracket, aligning the mounting holes. Thread in the mounting bolts by hand first to ensure proper thread engagement. Once all bolts are started, tighten them evenly using a torque wrench to the specified value. Ensure ballast is secure and not able to move.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Reconnect electrical connectors
   Connect the high-voltage output connector to the ballast first, ensuring it clicks into place securely. Then connect the main power connector, pressing firmly until the locking tab engages with an audible click. Gently tug on both connectors to verify they are fully seated and locked.
10. 10

    Test headlight operation
    Before reassembling other components, start the engine and turn on the headlights. The HID light should illuminate within 1-2 seconds and reach full brightness within 15-20 seconds. If the light does not turn on, turn off headlights immediately, wait 5 minutes, and verify all connections are secure. If problem persists, the issue may be the bulb or wiring rather than the ballast.

Reassembly

1. Once headlight function is verified, reinstall any wheel well liner push pins that were removed
2. Reinstall radiator cover panel (if equipped) by aligning clips and pressing firmly until seated
3. Close hood and verify all tools and parts have been removed from engine bay
4. Clean any fingerprints or dirt from headlight lens with appropriate cleaner

Verification

• With engine running, turn headlights on and verify both low beams illuminate properly within 20 seconds
• Switch to high beams and verify proper operation
• Turn headlights off and check that both lights extinguish
• Inspect ballast mounting area for any loose connections or hardware
• Take a short test drive after dark to verify proper light output and aim under real-world conditions

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