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

Warnings

Tools required

Parts

• LED headlight module assembly × 1 — Use OEM Ford part number for specific trim level
• Headlight module seal/gasket (if damaged) × 1 — Usually included with module

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key fob from vehicle interior
3. Open hood and secure with prop rod
4. Disconnect negative battery terminal and wait 2 minutes for electrical system to discharge
5. Allow engine to cool completely if recently driven (headlight area can retain heat)

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the negative battery terminal bolt. Remove the cable and secure it away from the battery post to prevent accidental reconnection during the repair.
   Torque spec

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

   Access headlight module mounting area
   Remove the plastic engine cover if equipped by pulling upward on the integrated pull tabs. This provides better access to the headlight assembly from the engine bay side. On the side being serviced, locate the headlight module mounting area behind the grille opening.
   ℹ️Some F-150 configurations have a partial grille removal required for easier access. Check clearance before proceeding.
3. 3

   Disconnect headlight electrical connectors
   Locate the main headlight harness connector at the rear of the headlight module. Press the release tab and pull the connector straight back. If equipped with adaptive headlights, disconnect the secondary leveling motor connector using the same method. Mark connectors with tape if multiple connections are present to ensure proper reassembly.
   ⚠Do not pull on wires. Always grasp the connector body. Connector locks can be brittle on high-mileage vehicles.
4. 4

   Remove headlight module mounting bolts
   Locate the three headlight module mounting bolts: one on the top outer edge, one on the top inner edge near the radiator support, and one accessible from below or through the wheel well. Remove all three bolts using an 8mm socket. Keep bolts organized for reinstallation.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
5. 5

   Remove retaining clips or screws
   Check for any additional plastic retaining clips or screws securing the headlight module to the fender or grille assembly. These may be located at the outer edge near the fender and along the bottom edge. Use a trim removal tool to carefully release any push clips without breaking them.
6. 6

   Extract headlight module
   Gently pull the headlight module forward and outward from the grille opening. The module may require slight angling to clear mounting tabs. Work slowly and check for any remaining connections or clips. Once clear, remove the module completely from the vehicle and place on a clean, padded surface with the lens facing up.
   ⚠Support the weight of the module during removal. Do not let it hang by any remaining clips or connections.
7. 7

   Inspect mounting points and clean surfaces
   Examine the headlight mounting area on the vehicle for any damage, corrosion, or debris. Clean the mounting surfaces with a microfiber cloth. Inspect the module seal/gasket for tears or deterioration. Check electrical connectors for corrosion or bent pins. Clean connector contacts with electrical contact cleaner if necessary.
8. 8

   Prepare new headlight module
   Remove the new LED headlight module from packaging. Verify it matches the old module design and connector configuration. Ensure any protective films or shipping materials are removed from the lens and housing. Check that the mounting seal is properly seated on the new module.
9. 9

   Install new headlight module
   Carefully position the new headlight module into the mounting location. Align the module with the grille opening and guide it rearward into position. Ensure all alignment tabs engage properly with their corresponding slots on the radiator support and fender. The module should sit flush with surrounding bodywork.
   ℹ️Do not force the module. If resistance is felt, remove and check for obstructions or misalignment.
10. 10

    Install mounting bolts
    Install the three headlight module mounting bolts and hand-tighten each one. Once all bolts are started, use a torque wrench to tighten them to specification in a cross pattern (top outer, bottom, top inner) to ensure even seating of the module.
    Torque spec

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

    Reinstall retaining clips
    Press any plastic retaining clips back into position until they click securely. Install any screws that were removed during disassembly. Verify the headlight module is firmly secured with no movement or gaps.
12. 12

    Reconnect electrical connectors
    Reconnect the main headlight harness connector by aligning it and pushing firmly until the release tab clicks into place. Reconnect the adaptive headlight leveling motor connector if equipped. Give each connector a gentle tug to verify it is fully seated and locked.
13. 13

    Reconnect battery and test
    Reinstall the negative battery cable to the battery terminal and torque the terminal bolt to specification. Turn the ignition to the ON position (engine off) and activate the headlights. Test low beam, high beam, and daytime running light functions. Check for proper operation and verify no warning lights appear on the instrument cluster.
    ℹ️If equipped with adaptive headlights, the system may require a brief initialization period or may display a temporary warning that clears after driving.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
14. 14

    Reinstall engine cover
    If the engine cover was removed, align it with the mounting grommets and press down firmly until all mounting points are seated. Close the hood.

Reassembly

1. Verify all electrical connections are secure and properly locked
2. Confirm headlight module sits flush with no gaps in surrounding bodywork
3. Check that all mounting bolts are torqued to specification
4. Ensure no tools or parts were left in the engine bay

Verification

• Start the engine and verify no warning lights related to headlight system appear
• Test all headlight functions: low beam, high beam, turn signals, and daytime running lights
• Visually inspect headlight alignment against a wall or garage door from 25 feet away - both headlights should project at same height
• If beam pattern appears significantly misaligned or adaptive headlight warnings persist, headlight aiming or dealer programming may be required
• Take a short test drive after dark to verify proper headlight operation and beam pattern

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