How do you replace the headlight assembly located on a 1994 Ford F-350 4x4?

Answer 1

First disconnect and remove the connections/bulbs to the headlamp, side marker light and turn signal. To remove the headlamp assembly you must first remove the headlamp "door". This is the plastic trim that surrounds the turn signal, headlamp and side marker light. To remove the headlamp door you must remove the two screws that attach the door to the front bracket. They are located on the top of the headlamp door, between the headlamp and the hood. Next, use a 7/16 socket to remove the two nuts that hold the turn signal light to the bracket. These nuts are located in recesses to the left and right of the headlamp in front of the battery or the washer/antifreeze reservoir (depending on which side you are working on). There is no need to remove the battery or the washer/antifreeze reservoir. They are recessed so you have to feel for them. The nut closest to the engine on each side may require a 1.5" socket extension as it is recessed a bit more than the nut on the fender side. After removal of the nuts slide the door assembly out, it will have the side marker and turn signal attached to it. This will expose the headlamp assembly itself. There are two silver headlamp retaining clamps on each side of the top of the headlamp. They are attached to adjusting nuts of the headlamp. These are removed by pulling upwards on them. Try not to damage the clamps as they will need to be reused on the new headlamp. There is a third headlamp retaining clamp on the fender side of the headlamp as well. It can only be seen/reached after removal of the headlamp door (hence the requirement to first remove the headlamp door). After removal of the three retaining clamps the headlamp assembly can be removed.

Reassemble in reverse order.

HEADLIGHT DOOR REMOVAL

I recommend removing the battery and the antifreeze/windshield washer reservoir. Two very simple task that made the job much easier for someone with very big hands. The driver side antifreeze/windshield washer reservoir only requires the removal of one nut (7/16). Once you have removed the one nut holding the reservoir to the bracket holding it in place, lift out towards the engine. It does not matter if the the reservoirs are full. This was the easiest of the sides to work on. You will have enough hose to simply rest it on the air filter housing. Passenger side proved a bit difficult even with the battery removed because of the battery platform. However, the job was much easier than having it in. Once you have disconnected the terminals, there is a small screw holding a support bracket in front, at the base of the battery. Remove it and you should be able to lift the battery out. When removing the two nuts that hold the turn signal and headlamp door, I recommend you have a telescoping magnet near by in case you drop the screw or the socket. The nut closest to the fender is hardest to work with.