Lighting
Headlights
REMOVAL & INSTALLATION
1997-98 F-250HD, F-350 And F-Super Duty
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Headlamp assembly—1997-98 F-250HD, F-350 And F-Super
Duty |
Click to enlarge
- Raise and support the hood.
- Disconnect the negative battery cable.
- Detach the headlamp electrical connector.
- Rotate the headlamp bulb retainer counterclockwise and remove.
- Remove the headlamp bulb by pulling it straight out with a gentle
up-and-down rocking motion.
| WARNING |
|
Do not touch the glass bulb with your fingers. Oil
from your fingers can severely shorten the life of the bulb. If
necessary, wipe off any dirt or oil from the bulb with rubbing alcohol
before completing installation. |
To
install:
- Install a new bulb into the headlamp assembly.
- Install the headlamp bulb retainer and turn it clockwise to engage the
retaining tabs.
- Attach the bulb electrical connector.
- Connect the negative battery cable.
- Turn the lights on and check the bulb operation.
F-150, F-250, Expedition And Navigator
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The headlamp assembly is held by two
retainers |
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Lift up on the retainers and ...
|
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... pull the headlamp assembly out of the front of the
vehicle |
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Detach the electrical connector for the headlamp
bulb |
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|
Rotate the retainer until ...
|
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... it is free from the retaining tabs on the headlamp
assembly and ... |
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... remove the bulb and retainer from the
headlamp |
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Remove the bulb from the
retainer |
| CAUTION |
|
The halogen bulb contains gas under pressure. The bulb
may shatter if the glass envelope is scratched or if the bulb is dropped.
Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching
the glass envelope. |
The headlamp bulb should not be removed from the headlamp until
just before a replacement bulb is installed. Removing the bulb for an extended
period of time may affect headlamp bulb performance. Contaminants may enter the
headlamp where they can settle on the lens and reflector. Never turn on the
headlamps with the bulb removed from the headlamp.
- Raise and support the hood.
- Disconnect the negative battery cable.
- Raise the headlamp retainers by pushing rearward and pulling up.
- If equipped, rotate the headlamp bulb protective cover counterclockwise
and remove.
- Disconnect the headlamp bulb electrical connector.
- Remove the headlamp assembly.
- Rotate the headlamp bulb retainer counterclockwise and remove.
- Remove the headlamp bulb by pulling it straight out with a gentle
up-and-down rocking motion.
| WARNING |
|
Do not touch the glass bulb with your fingers. Oil
from your fingers can severely shorten the life of the bulb. If
necessary, wipe off any dirt or oil from the bulb with rubbing alcohol
before completing installation. |
To
install:
- Install a new bulb into the headlamp assembly.
- Install the headlamp bulb retainer and turn it clockwise to engage the
retaining tabs.
- Attach the bulb electrical connector.
- If equipped, install the headlamp bulb protective cover.
- Install the headlamp assembly.
Be sure the headlamp assembly is positioned correctly with the
alignment pins inserted into the proper holes and onto the ribs of the
reinforcement.
- Engage the retainers by gently pushing down.
- Connect the negative battery cable.
- Turn the lights on and check the bulb operation.
1999-00 Super Duty Models
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|
Headlamp assembly—1999-00 Super Duty
models |
Click to enlarge
- Disconnect the negative battery cable.
- Pull up and remove the two upper headlamp clips.
- Release the lower headlamp clip.
- Position the headlamp so the connector can be accessed.
- Detach the headlamp connector.
- Remove the headlamp assembly from the vehicle.
- Rotate the headlamp bulb retainer counterclockwise and remove.
- Remove the headlamp bulb by pulling it straight out with a gentle
up-and-down rocking motion.
| WARNING |
|
Do not touch the glass bulb with your fingers. Oil
from your fingers can severely shorten the life of the bulb. If
necessary, wipe off any dirt or oil from the bulb with rubbing alcohol
before completing installation. |
To
install:
- Install a new bulb into the headlamp assembly.
- Install the headlamp bulb retainer and turn it clockwise to engage the
retaining tabs.
- Attach the bulb electrical connector.
- Install the headlamp assembly.
- Connect the negative battery cable.
- Turn the lights on and check the bulb operation.
AIMING THE HEADLIGHTS
The headlights must be properly aimed to provide the best, safest
road illumination. The lights should be checked for proper aim and adjusted as
necessary. Certain state and local authorities have requirements for headlight
aiming; these should be checked before adjustment is made.
| CAUTION |
|
About once a year, when the headlights are replaced or
any time front end work is performed on your vehicle, the headlight should
be accurately aimed by a reputable repair shop using the proper equipment.
Headlights not properly aimed can make it virtually impossible to see and
may blind other drivers on the road, possibly causing an accident. Note
that the following procedure is a temporary fix, until you can take your
vehicle to a repair shop for a proper adjustment.
|
Headlight adjustment may be temporarily made using a wall, as
described below, or on the rear of another vehicle. When adjusted, the lights
should not glare in oncoming car or truck windshields, nor should they
illuminate the passenger compartment of vehicles driving in front of you. These
adjustments are rough and should always be fine-tuned by a repair shop which is
equipped with headlight aiming tools. Improper adjustments may be both dangerous
and illegal.
For most of the vehicles covered by this manual, horizontal and
vertical aiming of each sealed beam unit is provided by two adjusting screws
which move the retaining ring and adjusting plate against the tension of a coil
spring. There is no adjustment for focus; this is done during headlight
manufacturing.
Because the composite headlight assembly is bolted into
position, no adjustment should be necessary or possible. Some applications,
however, may be bolted to an adjuster plate or may be retained by adjusting
screws. If so, follow this procedure when adjusting the lights, BUT always have
the adjustment checked by a reputable shop.
Before removing the headlight bulb or disturbing the headlamp in
any way, note the current settings in order to ease headlight adjustment upon
reassembly. If the high or low beam setting of the old lamp still works, this
can be done using the wall of a garage or a building:
- Park the vehicle on a level surface, with the fuel tank about
1/2 full and with the vehicle empty of all extra cargo
(unless normally carried). The vehicle should be facing a wall which is no
less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle
should be about 25 feet from the wall.
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|
Example of headlight adjustment screw location for
composite headlamps |
Click
to enlarge
- If aiming is to be performed outdoors, it is advisable to wait until dusk
in order to properly see the headlight beams on the wall. If done in a garage,
darken the area around the wall as much as possible by closing shades or
hanging cloth over the windows.
- Turn the headlights ON and mark the wall at the center of each
light's low beam, then switch on the brights and mark the center of each
light's high beam. A short length of masking tape which is visible from the
front of the vehicle may be used. Although marking all four positions is
advisable, marking one position from each light should be sufficient.
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|
Low-beam headlight pattern
alignment |
Click
to enlarge
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High-beam headlight pattern
alignment |
Click
to enlarge
- If neither beam on one side is working, and if another like-sized vehicle
is available, park the second one in the exact spot where the vehicle was and
mark the beams using the same-side light. Then switch the vehicles so the one
to be aimed is back in the original spot. It must be parked no closer to or
farther away from the wall than the second vehicle.
- Perform any necessary repairs, but make sure the vehicle is not moved, or
is returned to the exact spot from which the lights were marked. Turn the
headlights ON and adjust the beams to match the marks on the wall.
- Have the headlight adjustment checked as soon as possible by a reputable
repair shop.
Signal and Marker Lights
REMOVAL & INSTALLATION
Front Turn Signal and Parking Lights
1997-98 F-250HD, F-350 AND F-SUPER DUTY
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Parking and turn signal lamp bulb replacement—1997-98
F-250HD, F-350 And F-Super Duty |
Click to enlarge
- Disconnect the negative battery cable.
- Remove the headlamp assembly.
- Unplug the connector for the lamp.
- Turn the bulb and socket counterclockwise 1/4 of a
turn to release it from the lens.
- Pull the bulb straight out to remove it from the socket. To
install:
- Place a new bulb into the socket and gently push to engage the retaining
tabs.
- Place the bulb and socket assembly into the opening of the lens and turn
it 1/4 of a turn clockwise to engage it into the lens.
- Attach the connector for the lamp.
- Install the headlamp assembly.
- Connect the negative battery cable.
EXCEPT 1997-98 F-250HD, F-350 AND F-SUPER DUTY
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Turn the bulb and socket counterclockwise
1/4 of a turn to ... |
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... release it from the lens |
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Pull the bulb straight out to remove it from the socket
|
- Disconnect the negative battery cable.
- Open and support the hood.
- Remove the headlamp assembly.
- Turn the bulb and socket counterclockwise 1/4 of a
turn to release it from the lens.
- Pull the bulb straight out to remove it from the socket. To
install:
- Place a new bulb into the socket and gently push to engage the retaining
tabs.
- Place the bulb and socket assembly into the opening of the lens and turn
it 1/4 of a turn clockwise to engage it into the lens.
- Install the headlamp assembly.
- Connect the negative battery cable.
- Verify the operation of the lamp.
- Close the hood.
Side Marker Light
- Disconnect the negative battery cable.
- Carefully pry the lens from the lamp assembly.
- Remove the bulb from the terminals by gently pulling the bulb upward.
To install:
- Gently press the bulb into the terminals on the lamp.
- Snap the lens into the lamp assembly.
- Connect the negative battery cable.
- Verify the operation of the lamp.
Rear Turn Signal, Brake and Parking Lights
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The taillamp assembly is held by two retaining
screws—F-150 model shown |
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Remove the two taillamp retaining screws and ...
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... pull the taillamp assembly out of the rear of the
vehicle |
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Unplug the connector for the lamp
|
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Turn the bulb and socket counterclockwise
1/4 of a turn to release it from the lens
|
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Pull the bulb straight out to remove it from the socket
|
- Disconnect the negative battery cable.
- Remove the lamp retaining screws.
- Remove the lamp assembly from the vehicle.
- Unplug the connector for the lamp.
- Turn the bulb and socket counterclockwise 1/4 of a
turn to release it from the lens.
- Pull the bulb straight out to remove it from the socket. To
install:
- Place a new bulb into the socket and gently push to engage the retaining
tabs.
- Place the bulb and socket assembly into the opening of the lens and turn
it 1/4 of a turn clockwise to engage it into the lens.
- Attach the connector for the lamp.
- Place the lamp assembly into the opening in the vehicle.
- Tighten the lamp retaining screws.
- Connect the negative battery cable.
High-Mount Brake Light
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The high-mount brake light assembly is held to the body
by two retaining screws |
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Remove the two retaining screws and ...
|
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... remove the lamp assembly from the
body |
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Turn the bulb and socket counterclockwise
1/4 of a turn to release it from the lens
|
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Pull the bulb straight out to remove it from the
socket |
- Disconnect the negative battery cable.
- Remove the lamp retaining screws.
- Remove the lamp assembly from the vehicle.
- Unplug the connector for the lamp.
- Turn the bulb and socket counterclockwise 1/4 of a
turn to release it from the lens.
- Pull the bulb straight out to remove it from the socket. To
install:
- Place a new bulb into the socket and gently push to engage the retaining
tabs.
- Place the bulb and socket assembly into the opening of the lens and turn
it 1/4 of a turn clockwise to engage it into the lens.
- Attach the connector for the lamp.
- Place the lamp assembly into the opening in the vehicle.
- Tighten the lamp retaining screws.
- Connect the negative battery cable.
Dome Light
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Carefully pry the dome lamp lens from the lamp
assembly |
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Remove the bulb from the terminals by gently pulling
the bulb upward |
- Disconnect the negative battery cable.
- Carefully pry the dome lamp lens from the lamp assembly.
- Remove the bulb from the terminals by gently pulling the bulb downward.
To install:
- Gently press the bulb into the terminals on the lamp.
- Snap the lens into the lamp assembly.
- Connect the negative battery cable.
- Verify the operation of the lamp.
Map Lights
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Carefully pry the dome lamp lens from the lamp
assembly |
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Remove the three lamp assembly retaining screws and ...
|
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... lower the lamp assembly from the
headliner |
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Grasp the bulb and carefully remove it up and ...
|
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... out of the lamp assembly |
- Disconnect the negative battery cable.
- Carefully pry the dome lamp lens from the lamp assembly.
- Remove the three retaining screws for the map/dome lamp assembly and
remove it from the headliner.
- Remove the bulb(s) from the terminals by gently pulling the bulb upward
and out of the lamp assembly. To install:
- Slide the bulbs into place and gently press the bulb into the terminals on
the lamp.
- Place the lamp assembly into place and tighten the retaining screws.
- Snap the lens into the lamp assembly.
- Connect the negative battery cable.
- Verify the operation of the lamp.
Cargo Area Lamps
The cargo lamps are part of the high-mount brake lamp assembly.
Refer to high mount brake lamp in this section.
License Plate Lights
F-150, F-250, EXPEDITION AND NAVIGATOR
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Reach up and under the bumper to access the license
plate bulb socket, rotate the socket and remove it from the
lamp |
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Pull the bulb straight out to remove it from the socket
|
- Disconnect the negative battery cable.
- Reach under the bumper and rotate the bulb socket to remove it from the
lamp lens.
- Pull the bulb straight out to remove it from the socket. To
install:
- The installation is the reverse of the removal.
EXCEPT F-150, F-250, EXPEDITION AND NAVIGATOR
 |
|
Remove the lamp cover retaining screws to access the
license plate bulb |
Click to enlarge
- Disconnect the negative battery cable.
- Remove the retaining screws for the lamp lens.
- Remove the lens from the lamp assembly.
- Pull the bulb straight out to remove it from the socket. To
install:
- The installation is the reverse of the removal.
Fog/Driving Lights
REMOVAL & INSTALLATION
Lamp Assembly
- Disconnect the negative battery cable.
- Detach the bulb connector.
- Remove the retaining bolts and remove the lamp from the bracket. To
install:
- The installation is the reverse of the removal.
Bulb
- Disconnect the negative battery cable.
- Detach the bulb connector.
- Turn the bulb and socket counterclockwise 1/4 of a
turn to release it from the lens.
- Pull the bulb straight out to remove it from the socket. To
install:
- The installation is the reverse of the removal.
INSTALLING AFTERMARKET AUXILIARY LIGHTS
Before installing any aftermarket light, make sure it is legal
for road use. Most acceptable lights will have a DOT approval number. Also check
your local and regional inspection regulations. In certain areas, aftermarket
lights must be installed in a particular manner or they may not be legal for
inspection.
- Disconnect the negative battery cable.
- Unpack the contents of the light kit purchased. Place the contents in an
open space where you can easily retrieve a piece if needed.
- Choose a location for the lights. If you are installing fog lights, below
the bumper and apart from each other is desirable. Most fog lights are mounted
below or very close to the headlights. If you are installing driving lights,
above the bumper and close together is desirable. Most driving lights are
mounted between the headlights.
- Drill the needed hole(s) to mount the light. Install the light, and secure
using the supplied retainer nut and washer. Tighten the light mounting
hardware, but not the light adjustment nut or bolt.
- Install the relay that came with the light kit in the engine compartment,
in a rigid area, such as a fender. Always install the relay with the terminals
facing down. This will prevent water from entering the relay assembly.
- Using the wire supplied, locate the ground terminal on the relay, and
connect a length of wire from this terminal to a good ground source. You can
drill a hole and screw this wire to an inside piece of metal; just scrape the
paint away from the hole to ensure a good connection.
- Locate the light terminal on the relay; and attach a length of wire
between this terminal and the fog/driving lamps.
- Locate the ignition terminal on the relay, and connect a length of wire
between this terminal and the light switch.
- Find a suitable mounting location for the light switch and install. Some
examples of mounting areas are a location close to the main light switch,
auxiliary light position in the dash panel, if equipped, or in the center of
the dash panel.
- Depending on local and regional regulations, the other end of the switch
can be connected to a constant power source such as the battery, an ignition
opening in the fuse panel, or a parking or headlight wire.
- Locate the power terminal on the relay, and connect a wire with an in-line
fuse of at least 10 amperes between the terminal and the battery.
- With all the wires connected and tied up neatly, connect the negative
battery cable.
- Turn the lights ON and adjust the light pattern, if necessary.
AIMING
- Park the vehicle on level ground, so it is perpendicular to and, facing a
flat wall about 25 ft. (7.6m) away.
- Remove any stone shields, if equipped, and switch ON the lights.
- Loosen the mounting hardware of the lights so you can aim them as follows:
- The horizontal distance between the light beams on the wall should be the
same as between the lights themselves.
- The vertical height of the light beams above the ground should be 4 in.
(10cm) less than the distance between the ground and the center of the lamp
lenses for fog lights. For driving lights, the vertical height should be even
with the distance between the ground and the center of the lamp.
- Tighten the mounting hardware.
- Test to make sure the lights work correctly, and the light pattern is
even.
Instrument Cluster Light Bulbs
REMOVAL & INSTALLATION
- Disconnect the negative battery cable.
- Remove the instrument cluster as outlined in this section.
- Turn the desired bulb socket counter clockwise to remove it from the
cluster.
- Grasp the bulb and pull it straight out to remove it from the socket.
To install:
- Place a new bulb into the socket and lightly press it into place.
- Place the socket into the cluster and turn the socket clockwise to engage
it into the cluster.
- Install the instrument cluster.
- Connect the negative battery cable.