How to Replace a Headlight on a Ford Aerostar

The Aerostar was Ford Motor Company’s primary minivan for much of the 1990s. The Aerostar came equipped with halogen headlight bulbs which shine brighter, farther and last longer than their sealed beam predecessors. If the bulbs should burn out on your Aerostar, you need to replace them immediately. With a little mechanical inclination and a tool or two, you can have the bulb replaced in about 10 minutes.

Step 1 - Remove the screws that hold the headlamp trim bezel to the Aerostar using a Phillips head screwdriver. Pull the trim off.

Step 2 - Remove the headlamp retaining screws with the Phillips head screwdriver.

Step 3 - Pull the headlamp assembly outward, away from the front of the Aerostar. Disconnect the wiring harness from the back of the headlamp assembly by hand.

Step 4 - Pop the bulb retainer off the back of the headlamp assembly. You may need to pry it off with a pocket screwdriver. Pull the bulb out from the back of the headlamp assembly by hand.

Step 5 - Insert the new halogen bulb into the back of the headlamp and push the retaining clip into position. Do not touch the bulb’s glass with your hand as skin oils can damage the bulb.

Step 6 - Plug the wiring harness into the new bulb and place the headlamp assembly back into position.

Step 7 - Reinstall the headlamp retaining screws, trim bezel and trim bezel screws in reverse of removal.

THINGS YOU'LL NEED: Phillips head screwdriver, Pocket screwdriver (optional), Replacement halogen bulb

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