The driver's side headlight burned out on my van. I remove the battery thinking it would be a simple replaceable halogen bulb where you twist it out to remove. Instead it looks like the bulb is part of the headlight and the whole assembly needs to be replaced. There appear to be four screws that hold the assembly in place but three of them so rusted that I can not get them to turn.

Any ideas? I would hate to go to a mechanic for something so routine and simple but I don't think I have a choice now. The owner's manual is useless as it only addresses how to replace the bulb in the higher end highlights. My van has the standard square lights.

 

Sounds like you have old school H6054 glass bulb. Did you pull off the plastic trim? maybe you can spray the screws or get a pair of vice grips on em to loosen them. I usually just take 2 screws out of the top and bend the trim down to get bulb out.

 

Yes I removed the plastic trim that goes around the headlight. Then I sprayed the four screws with WD-40 and was only able to get one screw loose. I did not see any trim to bend down. It appears in order to get the headlight assembly out you have to remove all four screws. They are Phillip's head and did not want to strip them so I left it alone. That's the biggest problem with a 21 year old vehicle, everything is rusted to hell. What a pain, I wish it had the regular replaceable halogen bulbs that you just twist out.

 

Common problem with the headlight trim/retainer screws rusting out.

The trim is just light weight stainless steel, if both top screws can be removed, then the trim piece can be bent forward, and the bulb will come out, the problem is re-securing the trim to hold the bulb in place, I've used wire thur the bucket hole before cause the screw just stripped out of the bucket.

Replacement buckets are not available, alternative is using a mid '90's jeep cherokee headlight bucket and trim, will fit, and will work with the adjustment screws and spring retainer. Just note that the SS trim from the Ford will not work and you will need the Jeep SS trim.