Ford Car Parts UK - Quality Used, Genuine & New Parts

How to Replace Ford Headlights

Ford headlight replacement is straightforward on most models and follows a similar process across the range. Whether you're replacing halogen, xenon, or LED headlights on a Fiesta, Focus, Mondeo, or Kuga, these steps will guide you through the process. Ford headlights are generally accessible and easier to replace than many premium brands.

Step-by-Step Instructions:

1. Open the bonnet and locate the headlight assembly. Ford models generally have excellent access from the engine bay. On Fiesta and Focus, you can usually access from above after opening the bonnet. On Mondeo, you may need to remove the air intake ducting on one side for better access. Kuga and other SUV models have good clearance making access easier.
2. Disconnect electrical connectors. Ford headlights typically have 2-4 electrical connectors depending on the model and equipment level. These include main beam, dipped beam, side lights, and on equipped models, cornering lights or DRLs. Each connector has a release tab or twist-lock mechanism. Press the tab firmly and pull straight out, or twist counterclockwise and pull. On models with separate indicator units, disconnect the indicator connector as well.
3. Remove the headlight securing bolts or clips. Most Ford models use either 10mm bolts or Torx screws to secure headlights. Fiesta typically has 3 bolts along the top edge accessible from above. Focus has 2-3 bolts plus clips at the bottom. Mondeo headlights have 3-4 mounting bolts. Kuga has 3 bolts and clips. Remove all visible fixings before attempting to remove the headlight. Some models have plastic expanding clips that need releasing by pressing the center pin first.
4. Release any retaining clips. Many Ford headlights use additional plastic clips along the bottom or inner edges. On Fiesta, there's usually a clip at the inner bottom corner. On Focus, clips are located at the bottom edge and sometimes the inner edge. Press or pull these clips carefully as they can become brittle with age. Listen for clicks as clips release.
5. Carefully remove the headlight unit. Once all fixings and clips are released, gently pull the headlight forward and out of its mounting position. Ford headlights usually slide forward on locating pins or guide rails. Pull straight forward to clear the pins. Be careful not to scratch the bumper, wing, or grille paintwork during removal. The headlight should come out relatively easily once all fixings are properly released. Support the headlight as it comes free to prevent it dropping.
6. Transfer components if needed. If your replacement headlight doesn't include bulbs, carefully transfer them from the old unit. When handling halogen bulbs, wear gloves or use a clean cloth to avoid touching the glass with bare hands as skin oils cause premature bulb failure and can create hot spots. For models with separate bulb holders, transfer these carefully ensuring gaskets and seals are in good condition.
7. Install the new headlight. Reverse the removal process by aligning the new headlight with the mounting pins or guide rails. Push the headlight into place ensuring all locating pins engage properly and clips click into position. Refit all mounting bolts and tighten securely but don't overtighten as this can crack plastic housings or strip threads. Reconnect all electrical connections ensuring each connector clicks firmly into place. Test all lighting functions before final assembly including dipped beam, main beam, side lights, indicators, and any additional lighting such as DRLs or cornering lights.

Important Notes: When handling new headlights, avoid touching the lens or reflector surface as this can cause damage or reduce light output. Ford headlights on newer models with LED or adaptive lighting technology may require dealer programming or initialization to function correctly and prevent dashboard warning lights. Always check headlight alignment after fitting new units using the adjustment screws typically located on the back or side of the headlight assembly. Incorrect alignment can cause MOT failure and dazzle other drivers. For models with headlight leveling systems, ensure the leveling motor connector is properly reconnected. Some Ford models have headlight adjustment that can be performed using the dashboard controls once the headlight is fitted.

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How to Replace Ford Front Bumper

Replacing a Ford front bumper is a manageable DIY task that can be completed in 60-90 minutes depending on model and experience. This process is similar across Fiesta, Focus, Mondeo, Kuga, and other Ford models, though specific screw locations and clip positions vary by generation. Ford bumpers are designed for reasonable ease of replacement.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the upper bumper fixings along the top edge of the bumper below the grille and slam panel. Most Ford models have 4-8 screws or bolts securing the bumper to the upper radiator support. On Fiesta, these are typically Torx or Phillips screws. On Focus and Mondeo, there are usually 6-8 fixings across the top. Kuga has similar configurations with slightly more fixings due to larger size.
2. Remove upper mounting screws. Remove all screws or bolts along the top edge of the bumper. Keep all fixings organized by location as different lengths may be used in different positions. Some screws may be hidden behind plastic caps, the grille, or trim pieces that need to be prised off first. On some models, you may need to remove or partially release the grille to access additional fixings. Use your trim tool carefully to avoid breaking plastic tabs.
3. Access the wheel arch area. Turn the steering wheel fully to one side for better access to the wheel arch liner. Behind each front wheel, locate the plastic arch liner. You don't need to remove the entire liner—just remove 2-3 plastic clips or screws securing the front edge of the liner to expose the side bumper mounting points. Repeat on both sides. Plastic expanding clips are released by pressing the center pin first, then pulling the entire clip out.
4. Remove side mounting screws. Behind each wheel arch liner, you'll find 2-3 screws or bolts securing the bumper side to the wing. These are usually 10mm bolts or Torx screws on Ford models. Remove these fixings on both sides. Some models also have plastic clips that slide into the wing—these may release automatically when the bumper is pulled forward, or they may need manual release.
5. Remove undertray and lower fixings. Underneath the front of the car, locate and remove all screws and plastic clips securing the engine undertray and lower bumper section. Ford typically uses 8-12 fixings along the bottom edge. These may be Phillips screws, Torx screws, or plastic expanding clips. You may not need to completely remove the undertray—often you can just release the front section to access the lower bumper mounting points. For easier access, you can jack up the front of the vehicle and support it on axle stands, though this isn't always necessary.
6. Disconnect fog lights and sensors. Reach behind the bumper and disconnect all electrical connectors for fog lights (if fitted) and parking sensors (PDC). Press the release tabs carefully and pull connectors straight out. Most Ford models have 2-6 parking sensor connections if equipped. Count the number of connections you disconnect to ensure you reconnect them all during refitting. On models with active safety systems (Focus, Mondeo, Kuga), there may be radar or camera units behind the Ford badge that need disconnecting.
7. Release the bumper side clips. Ford bumpers are held by plastic clips or metal brackets on each side that slot into the wings. With all fixings removed, gently but firmly pull the bumper forward from one corner while supporting the opposite side. You may need to wiggle it slightly to release the clips. Work slowly and evenly to avoid breaking clips or scratching paintwork. Listen for clicks as the clips release. The clips can be tight on newer vehicles but will release with steady, even pressure.
8. Remove the bumper completely. With all fixings removed and connectors disconnected, carefully pull the bumper straight forward and completely away from the vehicle. Ford bumpers are reasonably lightweight but can be awkward to handle alone due to their size. Have someone assist if possible to avoid dropping or damaging the bumper. Place it carefully on a protected surface to avoid scratching the paintwork.
9. Fit the replacement bumper. Before fitting, transfer any brackets, clips, trim pieces, number plate mounting hardware, or tow eye covers from the old bumper to the new one if not already fitted. Align the new bumper with the mounting points and guide pins, then push it firmly into place ensuring all side clips engage properly. You should hear or feel clicks as clips locate correctly. Reconnect all electrical connections first (fog lights, parking sensors, radar/camera units if fitted), then secure with all screws, bolts, and clips in reverse order of removal. Always test all functions before final assembly including fog lights, parking sensors, and any active safety systems to ensure they're working correctly.

Top Tips: On ST and performance models with lower splitters or aerodynamic additions, take extra care when removing and fitting as these can be fragile. When refitting parking sensors, ensure they click firmly into their mounting holes and are correctly aligned to prevent false warnings or system malfunctions. Some Ford models have additional undertray panels or stone guards that must be refitted correctly to protect mechanical components. Always check the bumper mounting clips on the old bumper—if any are broken, you'll need to transfer good ones to the new bumper or purchase replacement clips from Ford parts suppliers. For models with active cruise control, lane-keeping assist, or collision avoidance systems (Focus, Mondeo, Kuga from 2016+), the front radar or camera may require recalibration at a Ford dealer after bumper replacement to ensure systems function correctly. Check all panel gaps are even before final tightening and adjust the bumper position if necessary.

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Common Ford Parts Problems & Solutions

Ford vehicles are popular across the UK for their practicality and driving dynamics, but certain components are prone to wear or failure across popular models. Here are the most common Ford parts issues based on verified data from UK owners, mechanics, and specialists:

Transmission Issues:

• Powershift Dual-Clutch Transmission Failure (Focus, Fiesta, EcoSport): The Powershift dual-clutch automatic transmission used in Focus, Fiesta, and EcoSport models from 2011-2016 is notorious for catastrophic failures and earned Ford millions in fines from consumer watchdogs. This is one of the most serious Ford reliability problems ever documented. The dry-clutch design suffers from premature clutch wear, control module failures, sensor faults, and mechanical component breakdowns. Symptoms include jerky or shuddering gear changes especially at low speeds, delayed acceleration or hesitation when pulling away, transmission slipping, complete transmission failure, clunking noises, difficulty selecting gears, and transmission warning lights. Problems typically occur between 30,000-80,000 miles but can happen much earlier. Ford initially refused to admit fault but eventually extended warranties and offered goodwill repairs after regulatory intervention. Powershift transmission replacement costs £3,000-£6,000+ from Ford dealers. Rebuilt transmissions cost £1,500-£3,000. Control module replacement costs £800-£1,500. The ACCC (Australian consumer watchdog) fined Ford for misleading conduct over this issue, and thousands of UK owners experienced similar problems. Many owners experienced multiple transmission failures even after repairs. This transmission is considered a complete disaster and should be avoided at all costs when buying used Fords. If you own one of these vehicles, ensure transmission oil is changed every 30,000-35,000 miles despite Ford's lifetime fluid claims, as this may extend transmission life slightly. Note that Mondeo uses a different wet-clutch Powershift design which is significantly more reliable and is NOT affected by these issues.
• Clutch Problems (Multiple Models): Clutch issues are common across Ford models particularly Focus, Fiesta, and Mondeo. Symptoms include clutch juddering or shuddering when pulling away, clutch pedal sticking to floor or not returning properly, difficulty changing gears, slipping clutch especially on hills, and burning smell. Common causes include worn clutch disc, failed release bearing, faulty clutch master or slave cylinder, and dual-mass flywheel failure (particularly on diesel models). Clutch replacement costs £400-£700 depending on model. Dual-mass flywheel replacement adds £300-£500. City driving with frequent stop-start traffic significantly accelerates clutch wear. Dual-mass flywheel rattling on diesel models (especially Mondeo and Focus diesels) is common between 80,000-120,000 miles and requires expensive flywheel replacement alongside clutch.

Engine & Mechanical Issues:

• EcoBoost Engine Problems (1.0L and 1.5L/1.6L 2.0L): Ford's EcoBoost turbocharged petrol engines, while praised for performance and fuel efficiency, suffer from numerous well-documented problems. The 1.0L EcoBoost (used in Fiesta, Focus, B-Max, EcoSport 2012-2018) experiences overheating issues, coolant loss, head gasket failures, and in extreme cases engine fires due to overheating. Symptoms include engine overheating, coolant loss without visible leaks, loss of power, rough running, white smoke from exhaust, and check engine light. Ford issued recalls for coolant sensor issues and modified engine management software to address overheating. However, problems persisted for many owners. Engine repairs cost £1,500-£3,000. Complete engine replacement costs £3,000-£5,000+. The 1.6L EcoBoost suffers from coolant intrusion into cylinders causing head gasket failure, typically between 50,000-100,000 miles. Regular coolant checks are essential. The 2.0L EcoBoost in Mondeo suffers from low-pressure fuel pump failures causing loss of power and stalling. Always ensure coolant is topped up and address any overheating immediately. Extended warranty coverage is strongly recommended for EcoBoost-equipped vehicles.
• Diesel Particulate Filter (DPF) Blocking (All Diesel Models): DPF blockages affect all Ford diesel models including Focus, Fiesta, Mondeo, Kuga, and Transit, particularly vehicles used primarily for short journeys where the DPF cannot regenerate properly. The DPF fills with soot that normally burns off during regeneration cycles on longer drives at higher speeds. Symptoms include DPF warning light on dashboard, loss of power and reduced acceleration, increased fuel consumption, limp mode activation limiting speed to 40-50 mph, rough idle, and excessive smoke. DPF problems are most common on vehicles doing lots of urban short trips. Professional DPF cleaning costs £150-£350. DPF replacement costs £800-£1,800 for genuine Ford parts. Prevention includes regular longer motorway journeys of at least 20-30 minutes at 50+ mph to allow regeneration, using correct low-ash engine oil, and ensuring the DPF regeneration cycle completes when initiated. Consider avoiding diesel Ford models if your driving is primarily short urban journeys.
• Timing Belt Failure (Transit 2.2 and 2.4 Duratorq Diesel): Ford Transit vans with 2.2L and 2.4L Duratorq diesel engines from 2006-2016 are prone to premature timing belt failure if not replaced at correct intervals. The timing belt should be replaced every 125,000 miles or 10 years, whichever comes first. Symptoms of impending failure include squealing noises from the engine, visible belt wear or cracking, and rough running. If the timing belt breaks, it causes catastrophic engine damage as these are interference engines where pistons strike valves. Timing belt replacement costs £400-£700 including water pump. Engine repair after belt failure costs £2,000-£4,000+ or may require complete engine replacement. Always replace timing belt at recommended intervals as preventive maintenance—this is critical on Transit vans.
• Exhaust Manifold Cracking (1.6 TDCi Diesel - Fiesta): Ford Fiesta models with 1.6 TDCi diesel engines from 2011-2017 commonly suffer from exhaust manifold cracking. The manifold develops cracks due to thermal stress and vibration. Symptoms include loud ticking or tapping noise from the engine especially when cold, exhaust smell in cabin, loss of power, and visible exhaust leaks. Exhaust manifold replacement costs £300-£600. This is a common failure on higher-mileage Fiesta diesels and is considered a design weakness.
• Turbocharger Failure (Diesel Models): Turbocharger problems affect Ford diesel models including Focus, Mondeo, Kuga, and Transit. Turbo failure typically occurs between 80,000-120,000 miles due to oil starvation, carbon buildup, or bearing wear. Symptoms include loss of power, excessive blue or black smoke from exhaust, whistling or whining noises, sluggish acceleration, and check engine light with boost pressure fault codes. Turbo replacement costs £700-£1,400 for aftermarket units, £1,400-£2,200 for genuine Ford parts. Regular oil changes with correct specification oil every 10,000 miles maximum and allowing the turbo to cool down by idling for 30 seconds after hard driving significantly extends turbo life.

Electrical & Electronics Issues:

• Engine ECU Failures (Focus Mk1, Mondeo Mk2/Mk3): Engine ECU failures are very common on Ford Focus Mk1 (1998-2004) and Mondeo Mk2/Mk3 (1998-2007) models. The ECU fails causing constant misfire on two cylinders, complete non-start, or no spark. This fault is usually caused by a faulty ignition coil pack shorting out and damaging the internal circuitry of the ECU. Symptoms include persistent misfire on two cylinders, rough running, loss of power, check engine light with misfire codes, and complete failure to start. ECU repair/rebuild costs £200-£400 from specialists. New ECU replacement costs £500-£800 plus programming. Critical note: when replacing a failed ECU, the ignition coil pack MUST be replaced at the same time or the faulty coil pack will damage the repaired ECU again immediately. This is an extremely common fault on these generation Focus and Mondeo models.
• Instrument Cluster Failures (Focus Mk2, Mondeo Mk4): Dashboard instrument cluster failures are very common on Focus Mk2 (2004-2011) and Mondeo Mk4 (2007-2014). The cluster develops faults causing loss of gauges, speedometer failure, mileage display failure, dash lights not working, and LCD screen malfunctions. Common fault code is U1900. Symptoms include speedometer not working (MOT failure), fuel gauge inaccurate or not working, temperature gauge not working, warning lights not functioning, and complete cluster failure. Instrument cluster repair costs £150-£300 from specialists. Replacement costs £200-£400. This is a well-documented problem on these generation Ford models.
• SYNC Infotainment System Problems (Multiple Models): Ford's SYNC infotainment system across Focus, Fiesta, Mondeo, and Kuga suffers from various glitches. Owners report freezing screens, unresponsive touchscreens, connectivity issues with smartphones, system crashes, and complete system failures. Problems affect SYNC 1, SYNC 2, and early SYNC 3 systems. Software updates from Ford dealers often resolve issues, though some require hardware replacement. Ford has released multiple software updates addressing these problems. Head unit replacement costs £400-£900 if hardware has failed. This is a common complaint across multiple Ford models and generations.
• Keyless Entry and Ignition Problems (Multiple Models): Keyless entry and keyless ignition systems on various Ford models can stop working intermittently or completely. Symptoms include key fob not being detected, unable to unlock or start the vehicle, system not recognizing key, and push-button start not working. Causes include key fob battery failure (most common and cheapest fix), faulty receiver module, antenna issues, and control module faults. Key fob battery replacement costs £5-£15. Key fob replacement costs £150-£300. Control module replacement costs £300-£600. Always try replacing the key fob battery first before expensive diagnostics.
• Body Control Module (BCM) Failures (Focus, Ranger): Body control modules in Focus and Ranger models commonly fail causing a range of electrical faults. Symptoms include interior lights not working, central locking malfunctions, window operation issues, dashboard warning lights, and various electrical gremlins. BCM replacement costs £200-£500 plus programming. This is a known issue particularly on 2011-2018 Focus and Ranger models.

Steering & Suspension Issues:

• Electric Power Steering Failures (Focus 2008, Fiesta 2017-2019): Electric power steering problems affect multiple Ford models. Focus ST from 2008 experienced power steering hose failures due to substandard hoses fitted during manufacturing, causing complete power steering failure. The hoses degraded over time causing leaks and loss of assistance. Ford issued recalls for affected vehicles. Power steering hose replacement costs £150-£500. Fiesta 2017-2019 models suffer from electric power steering column failures causing heavy or unresponsive steering, steering becoming stiff especially at low speeds, and EPS warning light. Electric power steering column replacement costs £400-£700. This is a safety-critical issue that should be addressed immediately if symptoms appear.
• Suspension Component Wear (Focus, Mondeo): Front suspension bushes and components wear prematurely on Focus and Mondeo models requiring earlier-than-expected replacement. Symptoms include knocking noises over bumps, clunking sounds from front suspension, uneven tire wear, and poor handling. Common worn components include front lower arm bushes, top mount bearings, anti-roll bar links, and ball joints. Suspension component replacement costs £200-£500 for both sides depending on which parts need replacing. Regular inspection helps catch wear early before it affects other components.

Braking System Issues:

• ABS Pump and Module Failures (Focus, Transit): ABS pump and module failures are common across Ford range particularly Focus and Transit models. The ABS system develops faults causing ABS warning light constantly illuminated, traction control light on, brakes locking or binding, and loss of ABS functionality. Common fault codes include C1095, C1288, and various pressure transducer codes. ABS pump module replacement costs £400-£700. Specialist rebuilders offer repair services for £250-£450. This is a common failure particularly on vehicles over 100,000 miles or 10+ years old.
• Rear Brake Problems (Focus, Fiesta): Rear brake issues affect Focus and Fiesta models. Rear disc brakes on Focus (2014-2018) wear prematurely and suffer from excessive brake dust. Rear drum brakes on Fiesta (2008-2017) require regular adjustment and can seize if not maintained. Symptoms include reduced braking efficiency, handbrake not holding properly, squealing noises, and uneven brake wear. Rear brake disc and pad replacement costs £150-£300. Rear drum brake overhaul costs £100-£200. Regular brake maintenance and cleaning helps prevent premature wear.

Other Common Issues:

• Fuel System Problems (1.0 EcoBoost): Fuel system issues plague the 1.0L EcoBoost engine. The low-pressure fuel pump commonly fails causing loss of power, hesitation, stalling, difficulty starting, and engine cutting out. High-pressure fuel pump failures also occur. Fuel injector problems cause rough running and misfires. Symptoms include sudden loss of power while driving, engine hesitation, check engine light with fuel system fault codes, and rough idle. Low-pressure fuel pump replacement costs £150-£300. High-pressure fuel pump replacement costs £400-£700. Fuel injector replacement costs £150-£300 per injector. This is a known weak point on 1.0 EcoBoost engines.
• Cooling System Failures (Multiple Models): Cooling system problems affect various Ford models. Engine overheating occurs due to thermostat failures, water pump failures, radiator leaks, and coolant sensor faults. Symptoms include engine overheating, coolant loss, temperature gauge fluctuating, heater not working, and engine warning lights. Thermostat replacement costs £100-£200. Water pump replacement costs £200-£400. Radiator replacement costs £200-£500. Regular coolant system maintenance including coolant changes every 5 years prevents many cooling system problems.
• Air Conditioning Condenser Failures (Multiple Models): Air conditioning condenser units commonly fail on Ford Mondeo models causing complete AC system failure. The condenser develops leaks or internal failures. Symptoms include AC not cooling, refrigerant leaks, and AC system not working at all. AC condenser replacement costs £200-£500. Regular AC servicing every 2 years helps maintain system performance and identify issues early.
• Electric Window Problems (Mondeo): Electric windows on Ford Mondeo have a peculiar fault where they wind down on their own when the car is parked. This is caused by faulty window control modules or switches. Symptoms include windows lowering themselves overnight or when parked, windows not operating correctly, and intermittent window operation. Window control module replacement costs £150-£350. This is a known Mondeo issue and can result in water damage to interior if not addressed.
• Diesel Fuel Injector Leaks (Mondeo Diesel): Diesel fuel injectors on Mondeo diesel models commonly develop leaks causing fuel smell and potential fire risk. If you can smell diesel fuel around the car when parked, there's likely an injector leak. Ford issued recalls to address this problem. Fuel injector replacement costs £150-£400 per injector. Check service history to verify recall completion. This is a safety issue that should be addressed immediately.

Model-Specific Issues:

• Fiesta 1.6 ST Cylinder Head Cracking (2013-2014): Some Ford Fiesta ST models with 1.6L engines built before 2014 suffered from cylinder head cracking caused by engine overheating. Ford issued recalls to address this problem. Symptoms include overheating, coolant loss, rough running, and white smoke. This should have been fixed under recall but check if any Fiesta ST you're considering has had the recall work completed. Cylinder head replacement costs £1,000-£2,000 if not covered under recall.
• Focus Powershift Transmission (2015 Models): Ford had multiple complaints from Focus owners with Powershift gearboxes from 2015 experiencing severe clutch slipping. Ford eventually installed a 6-speed manual system as a replacement on some affected vehicles due to the volume of failures. This underscores the severity of the Powershift transmission problems.

Prevention Tips: Ford vehicles require regular maintenance to remain reliable. More frequent oil changes (every 10,000 miles maximum) help prevent EcoBoost engine problems and turbo failures. For Powershift automatic transmission models, change transmission oil every 30,000-35,000 miles despite Ford's lifetime fluid claims—this may help extend transmission life though the design is fundamentally flawed. For diesel models used primarily for short journeys, ensure regular longer motorway runs (20-30 minutes at 50+ mph) to allow DPF regeneration. Replace timing belts on Transit vans at recommended intervals as preventive maintenance. Address any warning lights or unusual symptoms immediately as Ford vehicles can develop cascading failures where one problem causes others. When buying used Ford vehicles, thoroughly check service history and avoid Powershift automatic transmission models (Focus, Fiesta, EcoSport 2011-2016) unless you have comprehensive warranty coverage—these transmissions are a known liability. Check for recalls using your VIN and verify all recall work has been completed. Extended warranty coverage is recommended for EcoBoost-equipped vehicles and any high-mileage Ford over 80,000 miles due to common expensive failures including transmissions, ECUs, and major components.

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