This procedure covers the removal and replacement of the LED headlight module on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• LED headlight module assembly × 1 — Use OEM specification or aftermarket equivalent
• Push-pin retainers (if damaged) × 5 — Ford W710722-S300

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key from vehicle
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait 2 minutes for electrical system to discharge
5. Allow headlights to cool completely if recently operated

Procedure

1. 1

   Remove grille and access panels
   Remove the front grille by locating and removing the push-pin retainers along the top edge (typically 6-8 retainers). Pull the grille forward carefully to disengage the lower clips. For better access, remove the plastic air deflector panel below the headlight by removing 3-4 push-pins and setting aside.
2. 2

   Disconnect headlight electrical connectors
   Locate the main headlight connector at the rear of the module. Press the locking tab and pull the connector straight back. If equipped with additional connectors for DRL or side marker lights integrated into the assembly, disconnect those as well. Note the routing of wiring harnesses for reinstallation.
   ⚠Do not pull on wires; grasp connector bodies only to prevent damage to pins
3. 3

   Remove headlight mounting bolts
   Locate the three headlight module mounting bolts: one at the top outer corner (accessible from above), one at the inner top corner near the radiator support, and one at the lower inner corner (access from wheel well area or below). Remove all three bolts using 10mm socket.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
4. 4

   Disconnect leveling sensor (if equipped)
   For vehicles equipped with automatic headlight leveling, locate the leveling sensor connector and mounting on the rear of the headlight module. Disconnect the electrical connector by pressing the release tab. Remove the sensor mounting bolt and carefully separate the sensor linkage from the module.
   Torque spec

   Mounting Bolts42 Nm (31 lb-ft)
5. 5

   Remove headlight module from vehicle
   With all fasteners and connections removed, carefully pull the headlight module forward and outward. The module may require slight wiggling to clear alignment pins and tabs on the radiator support. Maneuver the module out through the front opening, being careful not to scratch the lens or damage surrounding bodywork.
6. 6

   Inspect mounting points and clean surfaces
   Examine the radiator support mounting points for damage, cracks, or corrosion. Check all alignment pins and tabs for integrity. Clean mounting surfaces with a clean rag to remove dirt and debris. Inspect electrical connectors for corrosion or damaged pins; clean with electrical contact cleaner if necessary.
7. 7

   Install new headlight module
   Position the new LED headlight module at the opening and align it with the mounting points on the radiator support. Ensure alignment pins engage properly. Push the module into place until it seats fully against the mounting surface. Verify the module sits flush with no gaps at the fender or grille mounting points.
   ℹ️Handle new module by edges only; avoid touching lens or LED components
8. 8

   Install mounting bolts
   Install all three headlight module mounting bolts finger-tight first to ensure proper alignment. Once all bolts are started, torque each bolt to specification in a cross pattern (top outer, then lower inner, then top inner) to ensure even seating of the module.
   Torque spec

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

   Reconnect leveling sensor (if equipped)
   Reattach the automatic leveling sensor to the mounting point on the rear of the headlight module and torque the mounting bolt to specification. Connect the sensor linkage ensuring full range of motion. Reconnect the electrical connector until it clicks into place.
   Torque spec

   Mounting Bolts42 Nm (31 lb-ft)
10. 10

    Reconnect electrical connectors
    Connect the main headlight connector to the module, ensuring it clicks and locks securely. Reconnect any additional connectors for DRL or marker lights. Route wiring harnesses along original path and secure with any clips that were removed. Ensure no wires are pinched or stressed.
11. 11

    Reinstall grille and panels
    Reinstall the air deflector panel below the headlight and secure with push-pin retainers. Align the front grille with mounting points and engage the lower clips first, then push firmly along the top edge while installing the push-pin retainers. Verify the grille is seated evenly on both sides.
12. 12

    Reconnect battery and initialize system
    Reconnect the negative battery terminal and torque to specification. If replacing with a different headlight module type or if equipped with adaptive lighting, connect a factory scan tool to perform headlight configuration and initialization. This may include setting headlight type, aiming parameters, and DRL settings.
    ℹ️Some F-150 configurations require scan tool programming when headlight modules are replaced
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm all mounting bolts are torqued to specification
3. Check that grille and trim panels are properly aligned and secured
4. Ensure no tools or parts were left in engine compartment

Verification

• Turn ignition to ON position and verify headlights illuminate properly in all modes (low beam, high beam, DRL)
• Check for proper operation of turn signals and side marker lights if integrated
• Verify automatic headlight leveling functions correctly if equipped by observing headlight aim changes when vehicle load changes
• Inspect headlight alignment and adjust if necessary using factory headlight aiming procedure
• Check for any warning lights on instrument cluster related to lighting system
• Verify no gaps exist between headlight module and surrounding body panels

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