This procedure covers the removal and replacement of the headlight assembly on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, including electrical disconnection and alignment.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — Use OEM specification
• Push pin retainers (if damaged) × 5 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn off all lights and ignition
3. Allow engine to cool if recently operated
4. Open hood and secure with prop rod
5. Disconnect battery negative terminal and wait 2 minutes for electrical system discharge

Procedure

1. 1

   Remove radiator grille cover panel
   Remove the upper radiator grille cover panel by releasing the push pin retainers along the top edge. Use trim removal tool to carefully pry up the center pins, then remove the entire retainer. Set panel and retainers aside in a safe location.
2. 2

   Access headlight mounting area
   With grille cover removed, locate the headlight assembly mounting points. There are typically three mounting bolts accessible from the top and one from the inner fender well area. Identify all mounting bolt locations before proceeding.
3. 3

   Disconnect headlight electrical connector
   Locate the main headlight electrical connector at the rear of the headlight assembly. Press the release tab and carefully pull the connector straight back to disconnect. For models with adaptive headlights, there may be an additional connector for the leveling motor—disconnect this as well.
   ⚠Do not pull on wires; always grasp the connector body to prevent wire damage.
4. 4

   Remove upper headlight mounting bolts
   Using a 10mm socket, remove the two or three upper headlight assembly mounting bolts accessible from the top of the assembly. Keep bolts organized for reinstallation. Support the headlight assembly with one hand as you remove the final bolt.
   Torque spec

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

   Remove lower mounting bolt
   Locate and remove the lower mounting bolt from the inner fender area. This may require reaching in from underneath or through the wheel well. Once removed, the headlight assembly should be free from the vehicle.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
6. 6

   Remove headlight assembly
   Carefully pull the headlight assembly forward and away from the vehicle. The assembly may have alignment tabs that need to disengage from slots in the body. Tilt or angle the assembly as needed to clear any obstructions. Place the old assembly on a protected surface if being saved.
7. 7

   Prepare new headlight assembly
   Remove any protective packaging or film from the new headlight assembly. Inspect the mounting tabs and alignment features to ensure they are not damaged. If the assembly includes new bulbs or LED modules, verify they are properly seated.
8. 8

   Install new headlight assembly
   Align the new headlight assembly with the body mounting points, ensuring alignment tabs engage properly with their slots. Carefully push the assembly into position until it seats flush against the body panel. The assembly should fit snugly without gaps.
9. 9

   Install mounting bolts
   Install all headlight assembly mounting bolts finger-tight first to ensure proper alignment. Once all bolts are started, torque each bolt 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

    Reconnect electrical connectors
    Reconnect the main headlight electrical connector by pushing it firmly into the socket until you hear or feel a positive click. If equipped with adaptive headlights, reconnect the leveling motor connector as well. Gently tug on connectors to verify they are locked in place.
11. 11

    Reinstall grille cover panel
    Position the radiator grille cover panel and align all mounting points. Install push pin retainers by inserting the outer portion first, then pressing the center pin down until flush. Verify all retainers are fully seated and the panel is secure.
12. 12

    Reconnect battery and test
    Reconnect the battery negative terminal and torque to specification. Turn on the ignition and verify all headlight functions operate correctly: low beam, high beam, turn signal, and daytime running lights. Check for proper operation of adaptive features if equipped.
    Torque spec

    Battery Terminal Bolts8 Nm (6 lb-ft)

Reassembly

1. Verify all mounting bolts are torqued to specification
2. Ensure no tools or parts are left in the engine compartment
3. Check that headlight assembly is flush with surrounding body panels with no gaps
4. Confirm all electrical connectors are fully seated and locked

Verification

• Test all headlight functions with ignition on: low beam, high beam, turn signals, parking lights, and daytime running lights
• Verify headlight beam pattern is correct and not aimed too high or low—adjust if necessary using adjuster screws
• Inspect headlight assembly alignment with body panels and ensure consistent gaps
• Check for any error messages or warning lights on the instrument cluster
• Test adaptive headlight features if equipped by turning steering wheel lock-to-lock with headlights on

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