This procedure covers the removal and replacement of the headlight assembly on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including proper alignment and electrical connection.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — Use OEM specification
• Plastic push clips (if damaged during removal) × 5 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn ignition off and remove key
3. Allow engine to cool for at least 30 minutes if recently driven
4. Open hood and secure with prop rod
5. Disconnect negative battery terminal to prevent electrical shorts

Procedure

1. 1

   Remove upper grille assembly
   Remove the upper grille by releasing the clips along the top edge. There are approximately 6-8 push clips securing the grille. Use a trim tool to gently pry the grille forward, starting from one side and working across. Once clips are released, pull the grille straight forward to remove.
2. 2

   Disconnect headlight electrical connectors
   Locate the main headlight electrical connector at the rear of the headlight assembly. Press the release tab and pull the connector straight back to disconnect. Repeat for the smaller side marker light connector if equipped. Label connectors if removing both headlights to ensure correct reassembly.
3. 3

   Remove headlight adjuster cover
   Locate the plastic access cover on top of the headlight assembly near the fender. Remove the cover screws using an 8mm socket. Keep these screws organized for reinstallation.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
4. 4

   Remove headlight assembly mounting bolts
   Locate the two headlight assembly mounting bolts accessible from the top of the assembly. Use a 10mm socket to remove these bolts completely. On some models, there may be a third bolt accessible through the wheel well area - if present, remove it as well.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
5. 5

   Release headlight from retaining clips
   With mounting bolts removed, gently pull the headlight assembly forward while checking for any remaining connections or clips. The assembly is secured by clips along the bottom edge that engage into the bumper. Apply steady pressure while lifting slightly to disengage these clips.
   ⚠Do not force the assembly - check for missed bolts or stuck clips if assembly does not release easily
6. 6

   Remove headlight assembly
   Once all fasteners and clips are released, carefully pull the headlight assembly straight forward and away from the vehicle. Support the assembly with both hands as it is removed to prevent dropping. Set the assembly on a clean, padded surface with the lens facing up.
7. 7

   Prepare new headlight assembly
   Remove new headlight assembly from packaging. Inspect for any shipping damage. Verify all adjustment mechanisms move freely. If transferring any components from old assembly (such as bulbs on some models), do so carefully following bulb replacement procedures.
8. 8

   Install new headlight assembly
   Position the new headlight assembly at the mounting location. Align the locating tabs on the bottom of the assembly with the slots in the bumper cover. Push the assembly rearward until the bottom clips engage and the mounting holes align with the vehicle mounting points.
9. 9

   Install headlight mounting bolts
   Install the headlight assembly mounting bolts finger-tight initially to allow for minor adjustment. Once all bolts are started, torque them to specification using a torque wrench in a cross-pattern to ensure even seating of the assembly.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
10. 10

    Reinstall adjuster cover
    Position the adjuster access cover over the adjustment screws on top of the headlight assembly. Install the cover screws and torque to specification.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
11. 11

    Reconnect electrical connectors
    Connect the main headlight electrical connector to the rear of the assembly, ensuring it clicks into place. Connect the side marker connector if equipped. Gently tug on each connector to verify it is fully seated and locked.
12. 12

    Reinstall upper grille
    Align the upper grille assembly with the mounting points on the vehicle. Push firmly along all clip locations until each clip snaps into place. Verify the grille is fully seated and flush with surrounding panels.
13. 13

    Reconnect battery and test
    Reconnect the negative battery terminal. Turn on the headlights and verify both low beam and high beam function correctly. Test turn signals and side marker lights. Check for proper operation of any adaptive lighting features if equipped.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify grille clips are fully engaged and grille is flush with fenders
3. Check that headlight assembly sits flush with surrounding body panels with no gaps
4. Reset clock and radio presets after battery reconnection

Verification

• Test all headlight functions including low beam, high beam, turn signals, and parking lights
• Visually inspect headlight alignment - beam pattern should be level and not aimed excessively high or to one side
• Check for any warning lights on the instrument cluster
• Perform a road test after dark to verify proper illumination and aim
• If headlight aim is significantly off, use headlight adjustment screws to perform rough adjustment - final aim should be verified with proper alignment equipment

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