Headlight still misaligned... projector issue?

I’ve replaced the headlights multiple times on my 2015 Ford Fusion and thought I was always getting the patterns right. Lately, though, the left headlight seems to be angled too far to the right. I took the bulb out and put it back in, pretty sure it’s in the right place. Could the projector be the problem?

Maybe you need to adjust the alignment.

My 2012 is doing the same, but it’s the opposite light.

Ira said:
My 2012 is doing the same, but it’s the opposite light.

It’s so strange. I swear it wasn’t like this before, and I’m unsure what changed. I’m thinking of replacing the whole assembly.

@Tanner
Same here. I made sure everything was seated properly and was really careful, but still no luck. I don’t have a fix for it.

@Tanner
I had the same issue. I replaced a burned-out bulb, and then I noticed a dark spot in front of the car. I switched to LED bulbs and adjusted them downwards. That seemed to fix the problem.

Maybe the bulb isn’t seated properly in the socket?

What kind of bulb are you using? If it’s adjustable, make sure it’s aimed at 9 o’clock and 3 o’clock.

Brook said:
What kind of bulb are you using? If it’s adjustable, make sure it’s aimed at 9 o’clock and 3 o’clock.

I’m using a halogen bulb. I’m pretty sure it’s locked in correctly.

@Tanner
Either it’s not locked in properly, or your projector could be damaged.

If the bulb isn’t seated just right, it can cause issues like what you’re seeing. I just remove the bumper and housing to get a better view of the bulb and make sure it’s properly placed. It’s a bit of a hassle, but it saves me from doing it too often.

@Zion
Thanks for the advice. I was hoping to avoid removing the bumper, but if nothing else works, I’ll try that. I’ve done it a few times without issues, but it’s frustrating this time.

Tanner said:
@Zion
Thanks for the advice. I was hoping to avoid removing the bumper, but if nothing else works, I’ll try that. I’ve done it a few times without issues, but it’s frustrating this time.

If it still doesn’t look right after adjusting, it could be a problem with the projector lens itself. Hopefully, that’s not the case. I’ve had no issues with my 2016 Fusion after double-checking the bulb seating.

@Zion
Thanks again. I’ll give it another shot tomorrow and maybe take off the bumper if needed.

Tanner said:
@Zion
Thanks for the advice. I was hoping to avoid removing the bumper, but if nothing else works, I’ll try that. I’ve done it a few times without issues, but it’s frustrating this time.

If you have small hands, it’s easy to get the headlight out. There are two 10mm bolts under the headlight and a few clips for the bumper. It’s a bit tricky to put back on, but it’s not hard.

@Karter
That’s what I did. Could the bulb be the issue? I’m wondering if it was only locked into two grooves or if the projector got knocked out of alignment when my son hit a curb. I’ll try again with the same bulb, and if it doesn’t work, I’ll just get a new assembly from eBay.

@Zion
Why are you replacing your headlights so often? What’s going on?

Stephen said:
@Zion
Why are you replacing your headlights so often? What’s going on?

The DRLs (Daytime Running Lights) are the low beams, and when the wipers are on, they automatically turn on. My partner does a lot of night driving, and we live in a rainy area. I use SilverStar Ultras, which have more light output but a shorter lifespan. They last about 125-150 hours.

@Zion
In the UK, DRLs are actually the high beams, and the low beams (H7) have their own housing.

You should try a quality LED bulb, like BEAMtech or Faren. If installed properly, they won’t cause glare, and they have sharp cutoff lines with more light output.