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Ford Fusion Headlight Bulbs Replacement Guide
How to change a low beam, high beam or front turn signal light bulb in a 2nd generation 2013-2016 Ford Fusion.

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2014 Ford Fusion Headlight
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Pry Out Center of Fastener
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Remove Entire Fastener

This automotive maintenance tutorial was specifically written to assist owners of the second generation (2013, 2014, 2015, 2016 and maybe also the updated 2017 model year) Ford Fusion sedan in changing a burnt out low beam, high beam or front turn signal light bulb in the headlight housings.

Owners of other Ford or Lincoln vehicles such as the Focus, Fiesta, C-Max, Mustang, Escape, Transit Connect, Edge, Flex, Explorer, Expedition, Taurus, F-150, EcoSport, MKC, MKZ, MKS, MKX, MKT and the Navigator may also find these DIY instructions to be helpful.

The replacement bulb part numbers are as follows: Low Beam # H11, High Beam # H7 and Front Turn Signal # PWY24W.

The tools needed to complete this procedure include a flathead screwdriver, a pair of needle nose pliers, Torx T30 & T25 screwdrivers, a 7mm socket and a 1/4" drive ratcheting wrench.

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Pry Up Center of Fastener
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Pry Up Other Fasteners
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Remove With Pliers
The first two steps are to open the hood and then move to the side of the vehicle with the burnt out headlight bulb.

In this tutorial, I'll show you how to change the bulbs in the driver side headlight housing. The procedure is the same for the passenger side.

Locate the pop rivet fasteners that secure the black plastic radiator cover trim panel to the front bumper fascia and the front of the engine bay.

Lift up the center part of each pop rivet first with the flathead screwdriver before prying out the base of the fastener.

You really only have to remove the four pop rivets at the front edge of the radiator cover.

I made the mistake of removing all 8 pop rivets and then I pulled off the entire radiator cover.

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Pull Off Radiator Cover
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9 Pop Rivets Removed
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Pry Up Bumper Cover Fastener
If you removed the radiator cover, set it aside in a safe place.

Pry out the larger pop rivet fastener on the bumper cover fascia right next to the inner corner of the headlight housing.

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Pull Out With Pliers
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10 Fasteners Removed
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Remove T30 Bolt
Pull out the base of the fastener with a flathead screwdriver or use a pair of needle nose pliers.

Remove the bolt on the top of the headlight assembly near the outer edge of the vehicle by turning it counterclockwise with a Torx T-30 star bit screwdriver.

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Outer Bolt Removed
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Remove T25 Bolt
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T30 & T25 Bolts Removed
Then remove the bolt on the left side of the headlight housing by turning it counterclockwise with the Torx T25 screwdriver.

Set the two bolts aside in a safe place.

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Turn Steering Wheel
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Wheel Well Liner
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Loosen Counterclockwise
The next step is to turn the steering all the way in the opposite direction of the burnt out headlight bulb.

Moving the front wheels will create more working room in the wheel well.

Locate the three fasteners on the front of the black plastic wheel well liner.

Loosen the thumb screws by turning them counterclockwise a few turns.

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Thumb Screw Fastener
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Remove 2nd Fastener
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Remove 3rd Fastener
Then pull out the three fasteners from the wheel well liner and set them aside in a safe place.
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13 Fasteners & 2 Bolts
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Under Corner of Bumper
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Loosen Thumb Screws
Move to the bottom corner of the fascia bumper cover.

Locate the three fasteners on the underside of the bumper cover. There are two black plastic fasteners and a black metal screw.

Remove the two black plastic thumb screws by rotating them counterclockwise before pulling out the base of the fasteners.

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Remove 2nd Thumb Screw
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Loosen 7mm Screw
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Turn Counterclockwise
Then loosen the screw at the front edge by turning it counterclockwise with a 7mm socket and 1/4" drive ratcheting wrench.

Set the 7mm screw aside in a safe place.

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15 Fasteners, 1 Screw, 2 Bolts
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Pull Back Wheel Well Liner
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Release Liner From Bumper
Gently pull back the plastic wheel well liner to separate it from the front bumper cover.
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Torx T-25 Bumper Screws
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Loosen Counterclockwise
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3rd Bumper Cover Upper Screw
Move to the top of the fascia bumper cover and locate the three metal screws.

Remove the three screws by turning them counterclockwise with a Torx T-25 star bit screwdriver.

Set the three screws aside in a safe place.

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All Screws & Fasteners
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Separate Side Bumper
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Gently Pull Forward
At this point, you'll have removed 15 plastic fasteners, 4 black metal screws, and 2 silver metal bolts.

Gently pull out the outside edge of the fascia bumper cover to separate it from the front quarter panel.

Very gently pull the front of the bumper cover forward away from the headlight assembly.

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Bumper Cover Loosened
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Pull Forward A Few Inches
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Pull Off Headlight Housing
Continue gently loosening the friction fastener clips on the front bumper cover until the bumper cover is a few inches away from the headlight.

The headlight housing is still held in place to the vehicle by a metal peg or "spike" that acts as a friction fastener.

Ford refers to the peg as the "lower fixing point".

Firmly pull the headlight housing straight forward to disengage the peg from its mounting socket.

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Metal Peg Disengaged
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Electrical Connector
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Slide Off Power Plug
Turn over the headlight housing to access the black plastic electrical connector.

Press in the release tab and slide the electrical connector straight out of it socket.

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Turn Over Assembly
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High Beam - Low Beam
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Rubber Dust Cover
The Low Beam headlight bulb is located at the center of the assembly.
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Pull Off Dust Cap
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1/4 Turn Counterclockwise
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Pull Out Old Bulb
Pull off the rubber dust cover and set it aside in a safe place.

Rotate the base of the old low beam bulb 1/4 turn counterclockwise and pull it straight out of the housing.



 

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Press Release Tab
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Old Bulb Disconnected
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Empty Bulb Socket
Press the release tab on the electrical connector and slide the plug straight off the base of the old low beam bulb.
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Push On Power Plug
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Insert New H11 Bulb
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1/4 Turn Clockwise - Lock
Try to avoid touching the glass part of the new halogen bulb with your fingers or anything dirty in the engine bay.

If you do get the new bulb dirty, wipe it clean with a paper towel moistened with rubbing alcohol.

Push the power plug straight on to the base of the new low beam bulb.

Insert the new # H11 low beam bulb in to the housing and rotate it 1/4 turn clockwise to secure it in place.

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Push On Round Rubber Cover
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High Beam Inner Corner
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Pull Off Rubber Cover
Push the black rubber dust cap back in to place over the new low beam bulb.

The High Beam light bulb is located near the inner corner of the headlight assembly.

Pull off the round black rubber dust cap from the back side of the housing.

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High Beam Light Bulb
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Pull Off Power Plug
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Release Arm From Hook
Gently pull off the black plastic electrical connector from the base of the old high beam bulb.

Push in the end of the metal retaining arm and release it from the hook.

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Swing Open Retaining Arm
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Pull Out Old High Beam
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Old Philips H7 Bulb
Swing open the metal retaining arm to release the old high beam bulb.

Pull the old high beam bulb straight out of the housing.

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Empty Bulb Housing
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Insert New # H7 Bulb
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Secure Retaining Arm
Try to avoid touching the glass part of the new high beam halogen bulb with your fingers or anything greasy in the engine bay.

If you do get the new bulb dirty, wipe it clean with a rubbing alcohol moistened paper towel.

Insert the new # H7 high beam bulb in to the housing.

Swing the metal retaining arm over the new bulb and attach it to the hook.

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Push On Power Plug
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Replace Rubber Cover
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Turn Signal Bulb Socket
Push the power plug straight on to the base of the new H7 high beam bulb.

Replace the black rubber dust cap over the new high beam bulb.

The Front Turn Signal light bulb is located at the outer edge of the headlight housing.

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1/4 Turn Counterclockwise
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Remove Bulb Socket
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Pull Out Retaining Clips
Rotate the base of the turn signal bulb socket 1/4 turn counterclockwise and pull it straight out of the housing.
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Loosen Clips
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Pull Out Old Turn Signal Bulb
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Philips PWY24W
Gently pry back the black plastic retaining clips that hold the old bulb in place.

Carefully pull the old bulb straight out of the socket.

Push a new # PWY24W turn signal bulb straight in to the socket.

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Re-Insert Bulb Socket
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1/4 Turn Clockwise
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Metal Peg / Spike
Re-insert the bulb socket in to the housing and rotate it 1/4 turn clockwise to secure it in place.
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Push On Power Plug
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Test New Headlight Bulbs
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Push On Headlight Assembly
Push the black plastic power plug straight in to its socket on the back side of the housing.

Before you go through the trouble of re-attaching the front bumper cover, test the new light bulbs by turning on the headlights, flashing the high beams and activating the hazard signals.

Line up the metal peg on the back side of the headlight housing with its socket on the front of the vehicle.

Firmly push the headlight housing back in to place.

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Tighten T30 Outer Screw
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Tighten Inner T25 Screw
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Headlight Assembly Flush
Re-insert the larger silver metal screw in to the hole closer to the outer edge of the headlight housing.

Tighten it in the clockwise direction with the Torx T30 star bit screwdriver until it is snug.

Then replace the smaller silver metal screw closer to the inner corner of the headlight housing and tighten it in the clockwise direction with the Torx T-25 screwdriver.

Make sure that the headlight housing is flush with the quarter panel.

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Line Up With Quarter Panel
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Re-Attach Fascia Cover
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Upper Bumper Cover Screws
Line up the outer edge of the bumper cover and re-attach it to the quarter panel.

Replace the three Torx T25 screws along the upper part of the front bumper cover by turning them clockwise.

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Replace 7mm Screw
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Re-Insert Fasteners
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Tighten Thumb Screws
Replace the 7mm screw on the underside of the bumper cover by turning it clockwise.

Re-insert the two black plastic fasteners on the underside of the bumper cover and tighten the thumb screws in the clockwise direction.

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Two Fasteners Replaced
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Wheel Well Liner Fasteners
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Re-Insert Thumb Screw
Move to the wheel well liner and re-insert the three black plastic fasteners.

Tighten the three thumb screws in the clockwise direction until they are snug.

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Tighten Thumb Screws
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3 Wheel Well Liner Fasteners
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Line Up Radiator Trim Cover
If you removed the black plastic radiator cover trim panel, lower it back down in to place.
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Re-Insert Pop Rivet
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Push In Center Piece
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Fastener Secured
Re-insert the large black plastic pop rivet in to the bumper cover near the inner corner of the headlight housing.

Push down the center part of the pop rivet to secure the fastener in place.

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Re-Insert Other Pop Rivets
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Push Down Center Part
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Radiator Cover Fasteners
Re-insert the other pop rivets that secure the radiator cover in place.
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Last Pop Rivet
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Radiator Cover Replaced
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Testing Headlight Bulbs
Double check that you have replaced all of the plastic pop rivet fasteners, black metal screws and silver metal bolts.

Test the new light bulbs by turning on the headlights, flashing the high beams and by activating the hazard signals.

For more, check out my other 2013-2016 Ford Fusion DIY Repair & Maintenance Guides.
 

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