Help, how to remove headlight 96 F350

[Tailwheel]

I can't figure out how to get my headlight assembly off. I have the factory manual and it is no real help. It says to remove the headlight door by removing 2 screws and 2 nuts. I think I found the screws but am not sure of where the nuts are located. There is a trim ring that I think should come off but there is no mention of it in the manual. Anyone got the magic handshake or decoder ring for this job?

Thanks

[Tailwheel]

I spent 5 hours and got the first one off. The second took about an hour. The "headlight door" is the headlight trim ring, the parking light and the turn signal. There are two 11mm nuts that are in blind locations. I removed the batteries for clearance and ended up having to repair the battery trays. One thing leads to another... Both had corrosion failed bolts and were able to move slightly. With the batteries the nuts can be touched but not seen and with a magnetic insert in a deep 11mm 1/4in drive they came out without a hitch. If the outboard one was to drop out of the socket it would be a nasty job to find. They are captive washer nuts so not easy to go get. The headlight has three twist lock plastic bolt holders and they came off the old lens by grinding the retaining lip off the lens in six places. All the old bolts were reusable. There are two clips that hold the top two lens adjusting bolts to the frame. These clips came off with a very stout pull and small long jaw Vise-Grips. I spent a lot of time trying to be gentle but in the end had to heave-ho. The "headlight door" assembly has to come off if you need to change a turn signal bulb. Nice design. I could do both now in less than an hour. If my arms were skinnier I could leave the batteries in and it would be a 30 minute job. I can't remove a battery without cleaning the cables.

[robertt253]

Originally Posted by Tailwheel

I spent 5 hours and got the first one off. The second took about an hour. The "headlight door" is the headlight trim ring, the parking light and the turn signal. There are two 11mm nuts that are in blind locations. I removed the batteries for clearance and ended up having to repair the battery trays. One thing leads to another... Both had corrosion failed bolts and were able to move slightly. With the batteries the nuts can be touched but not seen and with a magnetic insert in a deep 11mm 1/4in drive they came out without a hitch. If the outboard one was to drop out of the socket it would be a nasty job to find. They are captive washer nuts so not easy to go get. The headlight has three twist lock plastic bolt holders and they came off the old lens by grinding the retaining lip off the lens in six places. All the old bolts were reusable. There are two clips that hold the top two lens adjusting bolts to the frame. These clips came off with a very stout pull and small long jaw Vise-Grips. I spent a lot of time trying to be gentle but in the end had to heave-ho. The "headlight door" assembly has to come off if you need to change a turn signal bulb. Nice design. I could do both now in less than an hour. If my arms were skinnier I could leave the batteries in and it would be a 30 minute job. I can't remove a battery without cleaning the cables.

Thanks Tailwheel, I had been rying to figure out how to change that assembly for about a year now, your advise helped a lot. Allthough Ford Enginers should have their heads examined for making it so difficult.

Robert