How to change the headlight - headlamp - turnsignal bulb on a 1999-2003 Ford Windstar?

Answer 1

For model years 1999-2003, and most likely the entire Freestar / Monterey line too: The entire headlamp actually sits inside of a mounting bracket - this means it is very easy to fully release, and remove the headlamp to make bulb replacement much less *painful*! There are 2 headlight retainer clips to find - they are: 1) black, upside-down L-shaped metal clips about 1/2 inch wide 2) located just behind the top edge of the headlamp glass, inside the engine compartment. Release and pull the clips upward. The headlamp assembly will now pull forward providing great access to the electrical connector and bulb retainer ring. Picking up the *removal* instructions from the manual: * 3. Pull headlamp assembly forward disengaging the lamp from the rear retainer to expose the back of the bulb.

* 4. Disconnect the electrical connector from the bulb by pulling rearward.

* 5. Remove the bulb retaining ring by rotating it counterclockwise (when viewed from the rear) to free it from the bulb socket, and slide the ring off the plastic base. Keep the ring to retain the new bulb.

* 6. Without turning, remove the old bulb from its socket by gently pulling it straight back out of the lamp assembly. (You may have to wiggle it side-to-side a little while pulling rearward.) Installing the new bulb: NOTE: DO NOT TOUCH THE GLASS OF THE NEW BULB! The oil from your hand could cause the bulb to break the next time the headlamps are operated. # With the flat side of the new bulb's plastic base facing upward, insert the glass end of the bulb into the lamp assembly. Turn (rotate) the bulb left or right to align the grooves in the plastic base with the tabs in the lamp assembly. When the grooves are aligned, push the bulb into the lamp assembly until the plastic base contacts the rear of the lamp assembly.

# Install the bulb retain ring over the plastic base until contacts the rear of the socket by rotating clockwise until you feel a "stop."

# Connect the electrical connector into the rear of the plastic base unti it snaps, locking it into position.

# Install the headlamp on the vehicle by aligning the lamp with the rear retainer, push rearward and secure with two retainer pins.

# Turn the headlamps on and make sure they work properly. If the headlamp was correctly aligned before you changed the bulb, you should NOT need to align it again. With the cable unplugged, look at the back of the bulb assembly. You will see a small ring with three raised "ears". Rotate this counterclockwise about 120 degrees, and the 3 small square tabs under the ring can slip through the ring itself. Remove the ring. The bulb assembly is now exposed. Pull it straight back (away from you) to remove it. It has a rubber ring on the new bulb to seal the entire assembly from water. Do NOT remove the large rubber ring that goes around the retainer ring that you removed in the previous step. With the old bulb assembly removed, open the package for the new bulb. CAUTION: Do NOT touch the bulb itself. Fingertip oil, even very slight, can cause the bulb to fail very quickly. Holding the new bulb by the base, you will see 3 small detents (two of them rather close together, and the other on the opposite side of the base). Line these up with the corresponding marks on the headlight bezel assembly, and then push the bulb assembly gently into place. Once inserted, take the ring from the step above, slide it over the back of the bulb assembly and ensuring that the 3 square black tabs go through the square holes in the ring. Then, twist the ring clockwise about 120 degrees, using the "ears", until the ring is fully engaged. Check that you the square tabs are on the outside of the ring (it's easy to miss one, so that only two of the tabs are engaged - this can result in the bulb being loose). Just changed one on mine. Its easy. Under the hood there is a locking ring of sorts holding the lamp in place. Just grab two of the three knobs on this ring and give it a quarter turn. The locking ring pops off and the lamp assembly can be removed. Lift the plastic tab on the lamp holder and pull off the lamp socket. Reinstall in oposite order. Be sure not to touch the glass portion of the new lamp with your fingers -- wear gloves. The oil from your skin will shorten the lamp life if you do. It is possible to release the headlamp so it pulls out, making access to the connector (described above) much easier: NOTE: This procedure is detailed & illustrated in the Owner's Manual that came with the car, approximately page 246. The entire headlamp acutally sits inside of a mounting bracket - this means it is very easy to fully release, and remove the headlamp to make bulb replacement much less *painful*! There are 2 headlight retainer clips to find - they are: 1) black, upside-down L-shaped metal clips about 1/2 inch wide 2) located just behind the top edge of the headlamp glass, inside the engine compartment. Release and pull the clips upward. The headlamp assembly will now pull forward providing great access to the electrical connector and bulb retainer ring.
The following applies to 1999 - 2003 Windstars. Chances are these steps also apply to the Freestar and Mercury Monterey.

The entire headlamp housing assembly sits inside of a mounting bracket - this means it is very easy to fully release, and remove the headlamp to make bulb replacement much less *painful*!

There are 2 headlight retainer clips to find - they are:

1. black, upside-down L-shaped metal clips about 1/2 inch wide
2. located just behind the top edge of the headlamp glass, inside the engine compartment.

Release by pulling the top towards you while pulling the clips upward. The headlamp assembly will now pull forward providing great access to the electrical connector and bulb retainer ring.

Once you've pulled the entire headlight assembly outwards toward yourself, there is a small clip molded into the plug that has to clear the corresponding tab on the bulb assembly itself. You can pull it up SLIGHTLY while you pull the connector straight back (away from you) to remove the cable. Do not break the plastic clip - you only need to raise it about 1/16th inch to clear the tab.

With the cable unplugged, look at the back of the bulb assembly. You will see a small ring with three raised "ears". Rotate this counterclockwise about 120 degrees, and the 3 small square tabs under the ring can slip through the ring itself. Remove the ring.

The bulb assembly is now exposed. Pull it straight back (away from you) to remove it. It has a rubber ring on the new bulb to seal the entire assembly from water. Do NOT remove the large rubber ring that goes around the retainer ring that you removed in the previous step.

With the old bulb assembly removed, open the package for the new bulb. CAUTION: Do NOT touch the bulb itself. Fingertip oil, even very slight, can cause the bulb to fail very quickly. Holding the new bulb by the base, you will see 3 small detents (two of them rather close together, and the other on the opposite side of the base). Line these up with the corresponding marks on the headlight bezel assembly, and then push the bulb assembly gently into place. Once inserted, take the ring from the step above, slide it over the back of the bulb assembly and ensuring that the 3 square black tabs go through the square holes in the ring. Then, twist the ring clockwise about 120 degrees, using the "ears", until the ring is fully engaged. Check that you the square tabs are on the outside of the ring (it's easy to miss one, so that only two of the tabs are engaged - this can result in the bulb being loose).

Once locked in place with the ring, reattach the cable (the "D" shape of the plug matches the back of the bulb assembly), and press it into place until the small plastic clip goes up and over the tab on the bulb base, locking the cable in place.

Push the headlight bezel assembly back into place, push the "L" shaped metal tabs back into place (straight down, until they click), and test the light.

NOTE: This procedure is detailed & illustrated in the Owner's Manual that came with the car, approximately page 246.

The following applies to 1999 - 2003 Windstars. Chances are these steps also apply to the Freestar and Mecury Monterey. The entire headlamp housing assembly sits inside of a mounting bracket - this means it is very easy to fully release, and remove the headlamp to make bulb replacement much less *painful*! There are 2 headlight retainer clips to find - they are: # black, upside-down L-shaped metal clips about 1/2 inch wide # located just behind the top edge of the headlamp glass, inside the engine compartment. Release by pulling the top towards you while pulling the clips upward. The headlamp assembly will now pull forward providing great access to the electrical connector and bulb retainer ring.

Once you've pulled the entire headlight assembly outwards toward yourself, there is a small clip molded into the plug that has to clear the corresponding tab on the bulb assembly itself. You can pull it up SLIGHTLY while you pull the connector straight back (away from you) to remove the cable. Do not break the plastic clip - you only need to raise it about 1/16th inch to clear the tab. With the cable unplugged, look at the back of the bulb assembly. You will see a small ring with three raised "ears". Rotate this counterclockwise about 120 degrees, and the 3 small square tabs under the ring can slip through the ring itself. Remove the ring. The bulb assembly is now exposed. Pull it straight back (away from you) to remove it. It has a rubber ring on the new bulb to seal the entire assembly from water. Do NOT remove the large rubber ring that goes around the retainer ring that you removed in the previous step. With the old bulb assembly removed, open the package for the new bulb. CAUTION: Do NOT touch the bulb itself. Fingertip oil, even very slight, can cause the bulb to fail very quickly. Holding the new bulb by the base, you will see 3 small detents (two of them rather close together, and the other on the opposite side of the base). Line these up with the corresponding marks on the headlight bezel assembly, and then push the bulb assembly gently into place. Once inserted, take the ring from the step above, slide it over the back of the bulb assembly and ensuring that the 3 square black tabs go through the square holes in the ring. Then, twist the ring clockwise about 120 degrees, using the "ears", until the ring is fully engaged. Check that you the square tabs are on the outside of the ring (it's easy to miss one, so that only two of the tabs are engaged - this can result in the bulb being loose). Once locked in place with the ring, reattach the cable (the "D" shape of the plug matches the back of the bulb assembly), and press it into place until the small plastic clip goes up and over the tab on the bulb base, locking the cable in place. Push the headlight bezel assembly back into place, push the "L" shaped metal tabs back into place (straight down, until they click), and test the light. NOTE: This procedure is detailed & illustrated in the Owner's Manual that came with the car, approximately page 246.