96' Headlight replacement...Please help!
you have to take the the windshield washer fluid box and battery out, and then you can get back there and there is a nut on the back of a thread that is recessed in the metal. when you un-do those it allows you to take the bumper light and bezel off, the nuts will be recessed in the metal and you can see them because there will be like a half circle, opening where they will be, i just used a deep well socket 10mm i believe and got mine off. but be careful, mine broke off inside the old bumper light and got stuck in the truck and i had to drill it out, but once you get the bezel off theres only 2 screws that hold the head light on the truck..let me know how it goes and good luck
Last edited by 93F150cj; Oct 20, 2007 at 07:25 PM.
Gary, The headlight change is a rough one if rust has got to any of the fasteners,and it depends on how you want to attack the job.
You can do it like ford put it together or try and sneak them out leaving other things in place.
Ford mounted the headlights to the molded black panel and then screwed that to the core support. Then they put in the turn lamp assy. and headlight door in as an assembly.
Removing the special type clips which hold the headlights to the black panel is not easy when you are working with them in the truck and you want to save the clips.
If you don't care to save them,just jerk them loose and buy new ones if they bend or break.
The bottom line is ford did not put this together with any thought to getting it apart easily. It just works well and fast for the assembly line.
There are two nuts which hold the turnlamp and door assy which can be gotten to thru two cut out holes in the core support. If those nuts are rusted they will likely unscrew from the lamp housing before they come off the stud.
Once you have the turn lamps out you can access the two bolts at the outer edge of black molded frame which holds it to the core support, along with the other ones which were easy to see and get to.
I did this operation as ford put it together because I needed to replace a headlight door along with the headlights. It's easy to do except for the rust factor and having the molded piece off the truck makes it a bunch easier to replace the headlights and deal with those special clips which hold the lights in and also work with the light adjusting screws.
Those little clips hold the light in and also hold the adjuster nut from turning when aiming the headlight becomes necessary.
I don't know if the headlight can come through the opening if the door is left in place, it looks doubtful or at least tricky,but some guys have said nothing about removing the turnlamp and door assy. to replace the headlights.
Just don't plan on driving your truck the same day you start the operation, unless your name is Merlin !
I'll admit sometimes I'm slow but I didn't care if it got done in one day,nor was I getting paid by the hour. Hope this helps.
Dan
You can do it like ford put it together or try and sneak them out leaving other things in place.
Ford mounted the headlights to the molded black panel and then screwed that to the core support. Then they put in the turn lamp assy. and headlight door in as an assembly.
Removing the special type clips which hold the headlights to the black panel is not easy when you are working with them in the truck and you want to save the clips.
If you don't care to save them,just jerk them loose and buy new ones if they bend or break.
The bottom line is ford did not put this together with any thought to getting it apart easily. It just works well and fast for the assembly line.
There are two nuts which hold the turnlamp and door assy which can be gotten to thru two cut out holes in the core support. If those nuts are rusted they will likely unscrew from the lamp housing before they come off the stud.
Once you have the turn lamps out you can access the two bolts at the outer edge of black molded frame which holds it to the core support, along with the other ones which were easy to see and get to.
I did this operation as ford put it together because I needed to replace a headlight door along with the headlights. It's easy to do except for the rust factor and having the molded piece off the truck makes it a bunch easier to replace the headlights and deal with those special clips which hold the lights in and also work with the light adjusting screws.
Those little clips hold the light in and also hold the adjuster nut from turning when aiming the headlight becomes necessary.
I don't know if the headlight can come through the opening if the door is left in place, it looks doubtful or at least tricky,but some guys have said nothing about removing the turnlamp and door assy. to replace the headlights.
Just don't plan on driving your truck the same day you start the operation, unless your name is Merlin !
I'll admit sometimes I'm slow but I didn't care if it got done in one day,nor was I getting paid by the hour. Hope this helps.
Dan

