This procedure covers the removal and replacement of both left and right headlight assemblies on the 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including electrical connector service and alignment verification.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification or aftermarket equivalent
• Right headlight assembly × 1 — Use OEM specification or aftermarket equivalent
• Push pin retainers (if damaged) × 6 — Ford W714292-S439

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key fob from vehicle interior
3. Allow engine to cool completely if recently driven (minimum 30 minutes)
4. Open hood and secure with prop rod
5. Use masking tape to mark headlight vertical and horizontal aim position on wall or use existing alignment marks as reference for reinstallation

Procedure

1. 1

   Disconnect battery negative terminal
   Locate the battery in the engine compartment. Using a 10mm socket, loosen the negative terminal bolt and remove the cable from the battery post. Secure the cable away from the terminal to prevent accidental contact during the repair.
   Torque spec

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

   Remove radiator grille upper cover
   Remove the four push pin retainers securing the radiator grille upper cover panel. Use a panel removal tool or flat blade screwdriver to carefully pry the center of each push pin upward, then remove the entire pin. Lift the upper grille cover away from the vehicle and set aside.
3. 3

   Access headlight assembly mounting area
   Working from the top of the engine bay, locate the headlight assembly mounting bolts. There are three mounting bolts per headlight assembly: two accessible from the top and one from the inner fender area. Remove any wire harness clips or routing brackets that may interfere with headlight removal.
4. 4

   Disconnect driver side headlight electrical connectors
   Locate the main headlight electrical connector on the rear of the left headlight assembly. Press the connector release tab and pull the connector straight back from the headlight. If equipped with additional connectors for adaptive lighting or DRL modules, disconnect those as well. Note connector orientation for reassembly.
   ⚠Do not pull on wires; always grip the connector body to prevent wire damage.
5. 5

   Remove driver side headlight mounting bolts
   Using a 10mm socket, remove the two upper headlight mounting bolts. From the inner fender area, remove the third mounting bolt located on the outboard side of the headlight assembly. Keep all bolts organized for reinstallation.
   Torque spec

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

   Remove driver side headlight assembly
   Carefully pull the headlight assembly forward and outward from the vehicle. The assembly has locating tabs that engage with the fender and bumper cover. Tilt the assembly as needed to clear the mounting tabs. Place the assembly on a clean, padded surface with the lens facing up to prevent damage.
7. 7

   Disconnect passenger side headlight electrical connectors
   Repeat the connector disconnection process on the right headlight assembly. Press the connector release tab and pull the connector straight back from the headlight. Disconnect all additional connectors for adaptive lighting or DRL modules if equipped.
   ⚠Do not pull on wires; always grip the connector body to prevent wire damage.
8. 8

   Remove passenger side headlight mounting bolts
   Using a 10mm socket, remove the two upper headlight mounting bolts. From the inner fender area, remove the third mounting bolt located on the outboard side of the headlight assembly. Keep all bolts organized for reinstallation.
   Torque spec

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

   Remove passenger side headlight assembly
   Carefully pull the headlight assembly forward and outward from the vehicle. The assembly has locating tabs that engage with the fender and bumper cover. Tilt the assembly as needed to clear the mounting tabs. Place the assembly on a clean, padded surface with the lens facing up to prevent damage.
10. 10

    Install passenger side headlight assembly
    Position the new right headlight assembly, aligning the locating tabs with the slots in the fender and bumper cover. Press the assembly firmly into place ensuring all tabs are fully seated. Hand-start all three mounting bolts before tightening to ensure proper alignment.
    Torque spec

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

    Connect passenger side electrical connectors
    Reconnect all electrical connectors to the right headlight assembly, ensuring each connector is fully seated and the locking tab clicks into place. Verify connector orientation matches the original configuration. Route wiring harness through any retaining clips.
12. 12

    Install driver side headlight assembly
    Position the new left headlight assembly, aligning the locating tabs with the slots in the fender and bumper cover. Press the assembly firmly into place ensuring all tabs are fully seated. Hand-start all three mounting bolts before tightening to ensure proper alignment.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
13. 13

    Connect driver side electrical connectors
    Reconnect all electrical connectors to the left headlight assembly, ensuring each connector is fully seated and the locking tab clicks into place. Verify connector orientation matches the original configuration. Route wiring harness through any retaining clips.
14. 14

    Reinstall radiator grille upper cover
    Position the radiator grille upper cover panel and align mounting holes. Install all four push pin retainers by inserting the outer portion into the hole, then pressing the center pin down until it is flush with the outer portion and fully seated.
15. 15

    Reconnect battery and test headlights
    Reconnect the battery negative terminal cable to the battery post. Tighten the terminal bolt to specification using a torque wrench. Turn the ignition on and test all headlight functions including low beam, high beam, turn signals, and daytime running lights to verify proper operation.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify all three mounting bolts per headlight are torqued to 39.0 Nm (29.0 lb-ft)
3. Confirm headlight assemblies are flush with fender and bumper cover with no gaps
4. Check that all wire harness routing clips are secured to prevent chafing

Verification

• With ignition on, verify low beam headlights illuminate on both sides
• Verify high beam headlights function on both sides
• Test turn signal operation on both left and right headlight assemblies
• Check daytime running lights if equipped
• Verify no warning lights appear on instrument cluster related to lighting system
• Perform headlight aim adjustment using wall or alignment screen at 25 feet distance, adjusting to match original aim marks or to DOT specifications
• If equipped with adaptive headlights, verify system initialization completes without fault codes and steering angle sensor is centered

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