How to Replace 1995 F-150 Headlight Assembly

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Ford installed an aerodynamic headlight housing assembly on the 1995 F-150 trucks. The headlight assembly consists of a molded, plastic outer shell that protects the inner reflector surfaces and halogen light bulb. Ultraviolet rays from the sun will deteriorate the plastic shell over time, creating a hazed or cloudy finish, and reducing the light output of the headlight. If the headlight assembly is damaged, or the hazing cannot be buffed, replace the assembly as a unit to restore the headlight output.

Things You'll Need

  • Phillips screwdriver
  • Ratchet
  • Ratchet extension
  • Socket set
  • Measuring tape

Removal

  • Open the hood.

  • Remove the two upper screws from the headlight housing, using a Phillips screwdriver.

  • Locate the two lower retaining nuts inside the engine compartment at the bottom of the headlight housing. Remove the nuts using a ratchet, extension and socket.

  • Separate the turn signal and marker light assembly from the front grill. Rotate the bulb holders counterclockwise and pull them out of the assembly. Set the assembly aside.

  • Unplug the headlight bulb connector from the bulb. Rotate the retaining ring counterclockwise one-eighth turn and remove it from the housing. Pull the headlight bulb straight back and out of the housing. Do not rotate the bulb during disassembly.

  • Lift up on the headlight housing retaining clips to unsnap them from the headlight housing vertical adjuster studs.

  • Locate the horizontal adjuster at the outer bottom corner of the headlight assembly inside the engine compartment. Loosen the horizontal adjuster until it is free of the adjuster nut.

  • Remove the headlight housing from the vehicle.

Installation

  • Install the headlight housing in the front grill.

  • Engage the horizontal adjuster screw with the adjuster nut and screw it partially in.

  • Snap the headlight housing clips on the vertical headlight adjuster studs.

  • Insert the headlight bulb into the headlight housing, flat side up. Slightly rotate the headlight bulb to engage the grooves in the light with the alignment tabs in the back of the housing. Install the retaining ring on the bulb. Plug in the headlight bulb connector.

  • Install the bulb holders in the turn signal and marker light assembly. Install the assembly in the grill. Install the two upper screws, using a Phillips screwdriver. Install the two lower retaining nuts, using a ratchet, extension and socket.

Headlight Aiming

  • Pull the vehicle to within a few inches of a blank wall, on a flat surface. Apply two strips of tape to the wall vertically to mark the centers of the headlights. Apply a strip of tape to the wall horizontally to mark the center of the headlight height. Back the vehicle up 25 feet in a straight line.

  • Turn the headlight low beams to the “On” position.

  • Adjust the vertical headlight adjusters until the high-intensity zone of the light pattern is two inches below the horizontal mark on the wall.

  • Adjust the horizontal headlight adjusters until the high-intensity zone of the light pattern is two inches to the right of the vertical headlight marks on the wall.

Tips & Warnings

  • Halogen light bulbs are under pressure and may explode if dropped or scratched. Avoid touching the bulb with bare hands. Clean the bulb with rubbing alcohol if you do accidentally touch the bulb.

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References

  • Haynes Repair Manual, Ford Pick-ups and Broncos 1980 thru 1996; Mark Christman, et al.
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