# Lighting

## Headlights

### REMOVAL & INSTALLATION

#### 1997-98 F-250HD, F-350 And F-Super Duty

Headlamp assembly—1997-98 F-250HD, F-350 And F-Super Duty

Click to enlarge

1. Raise and support the hood.
2. Disconnect the negative battery cable.
3. Detach the headlamp electrical connector.
4. Rotate the headlamp bulb retainer counterclockwise and remove.
5. 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:
6. Install a new bulb into the headlamp assembly.
7. Install the headlamp bulb retainer and turn it clockwise to engage the retaining tabs.
8. Attach the bulb electrical connector.
9. Connect the negative battery cable.
10. Turn the lights on and check the bulb operation.

#### F-150, F-250, Expedition And Navigator

The headlamp assembly is held by two retainers

Lift up on the retainers and ...

... pull the headlamp assembly out of the front of the vehicle

Detach the electrical connector for the headlamp bulb

Rotate the retainer until ...

... it is free from the retaining tabs on the headlamp assembly and ...

... remove the bulb and retainer from the headlamp

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.

1. Raise and support the hood.
2. Disconnect the negative battery cable.
3. Raise the headlamp retainers by pushing rearward and pulling up.
4. If equipped, rotate the headlamp bulb protective cover counterclockwise and remove.
5. Disconnect the headlamp bulb electrical connector.
6. Remove the headlamp assembly.
7. Rotate the headlamp bulb retainer counterclockwise and remove.
8. 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:
9. Install a new bulb into the headlamp assembly.
10. Install the headlamp bulb retainer and turn it clockwise to engage the retaining tabs.
11. Attach the bulb electrical connector.
12. If equipped, install the headlamp bulb protective cover.
13. 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.

1. Engage the retainers by gently pushing down.
2. Connect the negative battery cable.
3. Turn the lights on and check the bulb operation.

#### 1999-00 Super Duty Models

Headlamp assembly—1999-00 Super Duty models

Click to enlarge

1. Disconnect the negative battery cable.
2. Pull up and remove the two upper headlamp clips.
3. Release the lower headlamp clip.
4. Position the headlamp so the connector can be accessed.
5. Detach the headlamp connector.
6. Remove the headlamp assembly from the vehicle.
7. Rotate the headlamp bulb retainer counterclockwise and remove.
8. 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:
9. Install a new bulb into the headlamp assembly.
10. Install the headlamp bulb retainer and turn it clockwise to engage the retaining tabs.
11. Attach the bulb electrical connector.
12. Install the headlamp assembly.
13. Connect the negative battery cable.
14. 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.

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.

Low-beam headlight pattern alignment

Click to enlarge

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

Parking and turn signal lamp bulb replacement—1997-98 F-250HD, F-350 And F-Super Duty

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the headlamp assembly.
3. Unplug the connector for the lamp.
4. Turn the bulb and socket counterclockwise 1/4 of a turn to release it from the lens.
5. Pull the bulb straight out to remove it from the socket. To install:
6. Place a new bulb into the socket and gently push to engage the retaining tabs.
7. 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.
8. Attach the connector for the lamp.
9. Install the headlamp assembly.
10. Connect the negative battery cable.

##### EXCEPT 1997-98 F-250HD, F-350 AND F-SUPER DUTY

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

1. Disconnect the negative battery cable.
2. Open and support the hood.
3. Remove the headlamp assembly.
4. Turn the bulb and socket counterclockwise 1/4 of a turn to release it from the lens.
5. Pull the bulb straight out to remove it from the socket. To install:
6. Place a new bulb into the socket and gently push to engage the retaining tabs.
7. 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.
8. Install the headlamp assembly.
9. Connect the negative battery cable.
10. Verify the operation of the lamp.
11. Close the hood.

#### Side Marker Light

1. Disconnect the negative battery cable.
2. Carefully pry the lens from the lamp assembly.
3. Remove the bulb from the terminals by gently pulling the bulb upward. To install:
4. Gently press the bulb into the terminals on the lamp.
5. Snap the lens into the lamp assembly.
6. Connect the negative battery cable.
7. Verify the operation of the lamp.

#### Rear Turn Signal, Brake and Parking Lights

The taillamp assembly is held by two retaining screws—F-150 model shown

Remove the two taillamp retaining screws and ...

... pull the taillamp assembly out of the rear of 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

1. Disconnect the negative battery cable.
2. Remove the lamp retaining screws.
3. Remove the lamp assembly from the vehicle.
4. Unplug the connector for the lamp.
5. Turn the bulb and socket counterclockwise 1/4 of a turn to release it from the lens.
6. Pull the bulb straight out to remove it from the socket. To install:
7. Place a new bulb into the socket and gently push to engage the retaining tabs.
8. 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.
9. Attach the connector for the lamp.
10. Place the lamp assembly into the opening in the vehicle.
11. Tighten the lamp retaining screws.
12. Connect the negative battery cable.

#### High-Mount Brake Light

The high-mount brake light assembly is held to the body by two retaining screws

Remove the two retaining screws and ...

... remove the lamp assembly from the body

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

1. Disconnect the negative battery cable.
2. Remove the lamp retaining screws.
3. Remove the lamp assembly from the vehicle.
4. Unplug the connector for the lamp.
5. Turn the bulb and socket counterclockwise 1/4 of a turn to release it from the lens.
6. Pull the bulb straight out to remove it from the socket. To install:
7. Place a new bulb into the socket and gently push to engage the retaining tabs.
8. 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.
9. Attach the connector for the lamp.
10. Place the lamp assembly into the opening in the vehicle.
11. Tighten the lamp retaining screws.
12. Connect the negative battery cable.

#### Dome Light

Carefully pry the dome lamp lens from the lamp assembly

Remove the bulb from the terminals by gently pulling the bulb upward

1. Disconnect the negative battery cable.
2. Carefully pry the dome lamp lens from the lamp assembly.
3. Remove the bulb from the terminals by gently pulling the bulb downward. To install:
4. Gently press the bulb into the terminals on the lamp.
5. Snap the lens into the lamp assembly.
6. Connect the negative battery cable.
7. Verify the operation of the lamp.

#### Map Lights

Carefully pry the dome lamp lens from the lamp assembly

Remove the three lamp assembly retaining screws and ...

... lower the lamp assembly from the headliner

Grasp the bulb and carefully remove it up and ...

... out of the lamp assembly

1. Disconnect the negative battery cable.
2. Carefully pry the dome lamp lens from the lamp assembly.
3. Remove the three retaining screws for the map/dome lamp assembly and remove it from the headliner.
4. Remove the bulb(s) from the terminals by gently pulling the bulb upward and out of the lamp assembly. To install:
5. Slide the bulbs into place and gently press the bulb into the terminals on the lamp.
6. Place the lamp assembly into place and tighten the retaining screws.
7. Snap the lens into the lamp assembly.
8. Connect the negative battery cable.
9. 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

Reach up and under the bumper to access the license plate bulb socket, rotate the socket and remove it from the lamp

Pull the bulb straight out to remove it from the socket

1. Disconnect the negative battery cable.
2. Reach under the bumper and rotate the bulb socket to remove it from the lamp lens.
3. Pull the bulb straight out to remove it from the socket. To install:
4. 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

1. Disconnect the negative battery cable.
2. Remove the retaining screws for the lamp lens.
3. Remove the lens from the lamp assembly.
4. Pull the bulb straight out to remove it from the socket. To install:
5. The installation is the reverse of the removal.

## Fog/Driving Lights

### REMOVAL & INSTALLATION

#### Lamp Assembly

1. Disconnect the negative battery cable.
2. Detach the bulb connector.
3. Remove the retaining bolts and remove the lamp from the bracket. To install:
4. The installation is the reverse of the removal.

#### Bulb

1. Disconnect the negative battery cable.
2. Detach the bulb connector.
3. Turn the bulb and socket counterclockwise 1/4 of a turn to release it from the lens.
4. Pull the bulb straight out to remove it from the socket. To install:
5. 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.

1. Disconnect the negative battery cable.
2. Unpack the contents of the light kit purchased. Place the contents in an open space where you can easily retrieve a piece if needed.
3. 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.
4. 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.
5. 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.
6. 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.
7. Locate the light terminal on the relay; and attach a length of wire between this terminal and the fog/driving lamps.
8. Locate the ignition terminal on the relay, and connect a length of wire between this terminal and the light switch.
9. 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.
10. 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.
11. 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.
12. With all the wires connected and tied up neatly, connect the negative battery cable.
13. Turn the lights ON and adjust the light pattern, if necessary.

### AIMING

1. Park the vehicle on level ground, so it is perpendicular to and, facing a flat wall about 25 ft. (7.6m) away.
2. Remove any stone shields, if equipped, and switch ON the lights.
3. Loosen the mounting hardware of the lights so you can aim them as follows:

1. The horizontal distance between the light beams on the wall should be the same as between the lights themselves.
2. 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.

1. Tighten the mounting hardware.
2. Test to make sure the lights work correctly, and the light pattern is even.

## Instrument Cluster Light Bulbs

### REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the instrument cluster as outlined in this section.
3. Turn the desired bulb socket counter clockwise to remove it from the cluster.
4. Grasp the bulb and pull it straight out to remove it from the socket. To install:
5. Place a new bulb into the socket and lightly press it into place.
6. Place the socket into the cluster and turn the socket clockwise to engage it into the cluster.
7. Install the instrument cluster.
8. Connect the negative battery cable.