This procedure covers removal and replacement of the headlight assembly on a 2015-2020 Ford F-150 with the 5.0L V8 Coyote engine, including electrical disconnection and proper alignment.

Warnings

Tools required

Parts

• Headlight assembly (specify left or right) × 1 — FL3Z-13008-A (LH) or FL3Z-13008-B (RH)
• Headlight assembly bolts (if corroded) × 3 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key
3. Allow headlights to cool if recently operated
4. Gather all tools and new headlight assembly
5. Mark headlight adjuster positions with tape if reusing adjusters for alignment reference

Procedure

1. 1

   Disconnect battery negative terminal
   Open hood and locate battery in engine compartment. Use 10mm socket to loosen negative battery terminal bolt. Remove negative cable and secure away from battery post to prevent accidental reconnection during repair.
   Torque spec

   Battery Terminal Bolts8 Nm (6 lb-ft)
2. 2

   Access headlight assembly mounting area
   Identify the headlight assembly to be replaced (driver or passenger side). Locate the three mounting bolts accessible from the engine bay side of the headlight housing. Two bolts are typically on top, one on the inboard side.
3. 3

   Disconnect headlight electrical connector
   Reach behind the headlight assembly and locate the main electrical connector. Press the release tab and pull the connector straight back to disconnect. If equipped with additional connectors for DRL or marker lights, disconnect these as well. Note connector orientation for reinstallation.
4. 4

   Remove headlight assembly mounting bolts
   Using 10mm socket, remove the three headlight assembly mounting bolts. Support the headlight assembly with your free hand to prevent it from falling once the last bolt is removed. Keep bolts organized for reinstallation.
   Torque spec

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

   Remove headlight assembly from vehicle
   Carefully pull the headlight assembly forward and out of the vehicle. The assembly may have alignment pins that require gentle wiggling to release. Check for any additional clips or retainers that may still be engaged before forcing the assembly.
6. 6

   Inspect mounting surfaces and alignment pins
   Examine the mounting bracket on the vehicle for damage, corrosion, or broken tabs. Clean mounting surfaces with a dry cloth. Inspect alignment pins for damage. Check that the radiator support area is not bent or damaged which would affect headlight alignment.
7. 7

   Prepare new headlight assembly
   Remove new headlight assembly from packaging carefully. Verify part number matches the side being replaced. Check that all adjustment screws move freely. Do not remove protective film from lens until after installation is complete.
8. 8

   Install new headlight assembly
   Guide the new headlight assembly into position, aligning the mounting pins with their corresponding holes in the radiator support. Ensure the assembly seats fully against the mounting surface before installing bolts. The gap between assembly and surrounding body panels should be even.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
9. 9

   Install and torque mounting bolts
   Hand-start all three headlight assembly mounting bolts to ensure proper thread engagement. Tighten bolts in a cross pattern (alternating between top and bottom) to ensure even seating. Torque all mounting bolts to specification using torque wrench.
   Torque spec

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

    Reconnect electrical connector
    Align the electrical connector with the headlight assembly socket, ensuring the connector tabs are properly oriented. Push connector firmly until you hear or feel a positive click indicating it is fully seated and locked.
11. 11

    Reconnect battery and verify operation
    Reconnect negative battery cable to battery post. Tighten battery terminal bolt to specification. Turn ignition to ON position (engine off) and test headlight operation including low beam, high beam, and turn signal functions.
    Torque spec

    Battery Terminal Bolts8 Nm (6 lb-ft)
12. 12

    Remove protective film and close hood
    Carefully peel off any protective film from the headlight lens. Inspect lens for scratches or damage. Close hood and verify there is no interference between hood and headlight assembly.

Reassembly

1. Torque all fasteners to specified values using proper torque wrench
2. Ensure all electrical connectors are fully seated with audible click
3. Verify even panel gaps around headlight assembly perimeter
4. Remove protective lens film only after installation is complete

Verification

• Test all headlight functions: low beam, high beam, turn signals, and parking lights
• Verify headlight assembly is secure with no movement when pressed
• Check for even panel gaps on all sides of headlight assembly
• Inspect for proper seating of all connectors with no exposed terminals
• Schedule headlight aim adjustment at earliest convenience; proper aim may require special equipment and cannot be fully verified without headlight aiming tools

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