Chrysler Car Parts UK - Quality Used & Genuine Parts

How to Replace Chrysler Headlights

Chrysler headlight replacement is straightforward on most models with good access from the engine bay. Whether replacing standard halogen units or upgrading to HID or LED headlights, this guide covers 300, Pacifica, and Voyager models.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the rear of the headlight assembly from within the engine bay. On the 300 sedan, access is straightforward with clear visibility to headlight mountings from above. On Pacifica and Voyager minivans, the higher bonnet line and spacious engine bay provide excellent clearance for reaching headlight components. Both models feature accessible mounting points designed for practical maintenance.
2. Disconnect all electrical connectors. Chrysler headlights typically have 2-3 electrical connectors depending on trim level and features. These include main beam, dipped beam, and side light connections. On higher trim levels with HID or LED headlights, additional connectors may be present for ballasts, leveling motors, or adaptive lighting systems. Press the release tabs carefully and pull straight out. Handle all connectors gently as plastic tabs can become brittle on older vehicles especially 2005-2015 models.
3. Remove the headlight mounting bolts. Most Chrysler models use standard 10mm bolts to secure the headlight assembly. On the 300, there are typically 2-3 bolts along the top edge easily accessible once the bonnet is open. On Pacifica and Voyager, expect 3-4 mounting bolts positioned for clear access from above. Remove all mounting bolts completely and keep them organized for reinstallation. Some models may have additional clips securing the bottom edge of the headlight.
4. Release any additional clips or retainers. Some Chrysler headlights use supplementary plastic clips at various points for additional security. On 300 models, check for clips at the inner corner near the grille area. On Pacifica and Voyager, look for clips at the bottom edge near the bumper. Work carefully as clips can become brittle with age especially on vehicles exposed to harsh weather conditions. If clips break during removal, replacement clips are available from breakers or dealers.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. Chrysler headlights slide forward on locating pins and tabs that ensure correct alignment. Support the weight as you pull to prevent dropping. If you feel resistance, stop and check for missed fixings rather than forcing. The 300 headlights are moderately heavy, while Pacifica and Voyager units are larger but designed for easy handling.
6. Transfer components to new headlight if needed. If your replacement headlight doesn't include bulbs, leveling motors, or ballasts for HID systems, carefully transfer these from the old unit to the new one. When handling bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as skin oils cause premature failure and hotspots. HID bulbs are particularly sensitive to contamination. Take care not to overtighten bulb retaining clips as this can damage the new headlight housing.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting pins and locating tabs. Push firmly into place ensuring all pins engage correctly in their corresponding holes. Refit all mounting bolts and tighten securely but avoid overtightening which can crack the headlight housing. Reconnect all electrical connections ensuring each clicks firmly into place. Test all lighting functions before final assembly including dipped beam, main beam, side lights, indicators, and daytime running lights if equipped. Check headlight alignment and adjust if necessary using adjustment screws on the rear of the assembly.

Important Notes: Chrysler headlight replacement is straightforward with good access on all models. When handling new headlights, never touch lens or reflector surfaces as fingerprints reduce light output. HID headlights may require coding or initialization to avoid dashboard warning lights. Check headlight alignment after fitting as proper alignment is crucial for visibility and MOT compliance. On 300 models with adaptive headlights, ensure the system completes its self-calibration by starting the engine and turning the steering wheel lock-to-lock.

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How to Replace Chrysler Front Bumper

Replacing a Chrysler front bumper is achievable in 60-90 minutes depending on model and trim level. This process covers 300, Pacifica, and Voyager models, though specific fastener locations vary between sedans and minivans.

Step-by-Step Instructions:

1. Open the bonnet and secure it with the prop rod. Locate the upper bumper mounting fixings along the top edge. On the 300 sedan, there are typically 4-6 bolts or screws securing the bumper from above, positioned just below the grille and headlights. On Pacifica and Voyager minivans, expect 6-8 fixings across the top due to the larger bumper size. These are usually 10mm bolts or Phillips screws. Remove all upper fixings systematically and store them safely as they're crucial for proper reinstallation.
2. Access the wheel arch areas on both sides. Turn the steering wheel fully to one side to maximize access to the front wheel arch liner. Behind each front wheel, locate the plastic arch liner that covers the area between the wheel and bodywork. Remove or release 3-5 plastic clips or screws securing the front section of the arch liner to expose side bumper mounting points. Chrysler typically uses push-in plastic clips that release by pressing the center pin before pulling the entire clip out. Some models use Phillips screws instead. Repeat on both driver and passenger sides.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, you'll find 2-4 screws or bolts securing each side of the bumper to the wing and chassis. These are usually 10mm bolts or 7mm screws on Chrysler models. Remove all side fixings on both left and right sides. Keep track of which fixings came from which location if they differ in length or type. On 300 models, these are typically bolts, while Pacifica and Voyager may use a combination of bolts and screws.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. Never work under a vehicle supported only by a jack. Locate and remove all screws and clips securing the engine undertray and lower edge of the bumper. Chrysler typically uses 8-15 fixings along the bottom edge. These may be Phillips screws, 10mm bolts, or plastic push-in clips. You may not need to remove the entire undertray, just release the sections that connect to the bumper. On Pacifica and Voyager, the undertray is more extensive due to the larger vehicle size.
5. Disconnect sensors, fog lights, and electrical connections. Reach behind the bumper and disconnect all electrical connectors. This includes parking sensor connections if equipped with park assist, fog light connections if fitted, and any additional wiring for active grille shutters on newer models. On Pacifica and Voyager, there may be additional connections for cameras or pedestrian detection systems. Press release tabs carefully and pull straight out. Count how many connections you disconnect to ensure you reconnect them all during refitting. Label connections if necessary to avoid confusion.
6. Release the bumper side clips and mounting tabs. Chrysler bumpers are secured by plastic clips or metal brackets on each side that slot into the wing panels. With all fixings removed, firmly but gently pull the bumper forward from one corner while a helper supports the opposite side. You may need to wiggle slightly to release the clips. Listen for clicks as clips disengage. The bumper should slide forward once all clips are released. If the bumper doesn't move freely, stop and check for missed fixings rather than forcing it.
7. Remove the bumper completely from the vehicle. With all fixings removed and clips released, carefully pull the bumper straight forward away from the vehicle. On the 300 sedan, one person can typically handle the bumper removal, but Pacifica and Voyager bumpers are large and benefit significantly from a second person to prevent dropping or scratching. Place the removed bumper on a protected surface such as cardboard or blankets to avoid damaging the painted surface or crushing parking sensors.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any components from the old bumper if not fitted to your replacement including parking sensor holders and sensors, fog light mounting brackets and bulbs, licence plate holder and mounting hardware, trim strips, chrome accents, or badges, and any mounting brackets or reinforcement bars. Align the new bumper with mounting points ensuring side clips are positioned to engage with their slots in the wings. Push firmly into place ensuring all side clips engage properly with audible clicks. Reconnect all electrical connections including parking sensors, fog lights, and cameras. Systematically secure with all screws, bolts, and clips in reverse order of removal. Test all electrical functions before final assembly including parking sensors beeping when objects approach, fog lights illuminating, and camera displaying properly. Check panel gaps are even on both sides and the bumper sits flush with wings and grille.

Top Tips: Chrysler bumpers are designed for practical replacement with reasonable access. When refitting parking sensors, ensure each clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. Test sensors after installation by approaching objects to confirm they beep at appropriate distances. On Pacifica and Voyager models with front-mounted cameras for 360-degree view or forward collision warning, these may require recalibration at a Chrysler dealer after bumper replacement. Check all panel gaps between bumper and wings are even before final tightening of all bolts. Chrysler's manufacturing tolerances mean replacement parts typically fit well without extensive adjustment. Take photos during disassembly to reference during reassembly if needed.

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Common Chrysler Parts Problems & Solutions

Chrysler vehicles offer good value in their respective segments. RepairPal ranks Chrysler 11th out of 32 brands with average annual repair costs of £608 versus £652 industry average, making it the most reliable domestic American brand. However, certain components experience specific recurring issues. Here are the most commonly reported Chrysler parts problems based on verified data from UK owners, mechanics, NHTSA reports, and industry specialists.

Transmission Problems (2017-2024 Pacifica and Voyager) - Most Critical Issue:

• Nine-Speed Transmission Issues: The 2017-2024 Chrysler Pacifica and Voyager equipped with the ZF nine-speed automatic transmission experience widespread transmission problems. Hard or rough shifting is extremely common, particularly noticeable at 40-45 mph and 50-55 mph when easing off the throttle. Drivers report uncomfortable jerky transitions that make the vehicle feel poorly refined. Delayed engagement when shifting from park to drive or reverse is another frequent complaint, with the transmission hesitating before engaging gears. Jerking motions during acceleration or deceleration affect driving smoothness. Complete transmission failure requiring full replacement has been reported on numerous vehicles, particularly 2017-2018 models. Symptoms typically start appearing at relatively low mileage around 20,000 miles on vehicles only 1-2 years old.
• Root Causes and Repairs: Software glitches in the Transmission Control Module (TCM) contribute to shifting problems. Chrysler has released software updates and recalibrations that provide temporary relief for some owners, though problems often return. In many cases, complete transmission replacement is the only lasting solution. Repair costs for transmission replacement range from £3,000-£5,000 depending on whether remanufactured or new units are installed. Regular transmission fluid and filter changes at 60,000-mile intervals as recommended may help extend transmission life, though many failures occur well before this mileage. The 2017-2018 model years are particularly problematic with significantly higher failure rates than later years. When buying used Pacifica or Voyager from these years, factor potential transmission costs into purchase decisions or verify transmission has already been replaced under warranty.

Engine Stalling and Power Loss (2017-2024 Pacifica Hybrid):

• Sudden Shutdowns While Driving: One of the most dangerous issues affecting Chrysler Pacifica, particularly hybrid models, is the engine randomly stalling or shutting down while driving. Drivers report receiving a dashboard warning message "Stop Safely, Vehicle Will Shut Off Soon" moments before losing all power. This creates serious safety risks especially on motorways where sudden power loss at speed can cause crashes. Complete loss of power without warning has also been reported. Battery and charging system malfunctions including battery coolant leaks contribute to these shutdowns. NHTSA has opened investigations into this issue due to safety concerns.
• Additional Engine Problems: Engine overheating linked to low coolant levels or faulty head gaskets affects particularly 2017-2018 models. Overheating can cause catastrophic engine damage if not addressed immediately. Oil leaks and excessive oil consumption requiring frequent top-ups between oil changes plague many Pacifica owners. Knocking or ticking noises from the engine indicate potential internal wear or valve train issues. Engine problems combined with sudden stalling make reliability a serious concern on earlier Pacifica models. Regular coolant level monitoring and immediate attention to temperature gauge warnings are essential.

UConnect Infotainment System Failures - Widespread Problem:

• Frozen Screens and Black Displays: UConnect infotainment systems across Chrysler models will often boot into a blank black screen, freeze while the vehicle is in reverse making backup cameras unusable, become completely unresponsive to touch inputs, or reboot randomly while driving. The system has grown over the years in both size and features, but software stability remains problematic. On Pacifica and Voyager, the large touchscreen controls critical vehicle functions including climate control, making failures particularly frustrating. Class-action lawsuits have been filed over UConnect reliability issues.
• Connectivity and Software Issues: Apple CarPlay and Android Auto connections frequently fail or behave erratically. Bluetooth pairing drops unexpectedly. Navigation systems freeze or provide incorrect directions. Radio software preventing rearview camera images from displaying led to NHTSA recalls affecting 2021-2023 Pacifica, Voyager, and other Stellantis vehicles under campaign numbers 66B and 79B. Dealers update radio software or provide over-the-air updates free of charge. Despite updates, many owners continue experiencing intermittent UConnect problems that dealers struggle to diagnose because they're often not present during service appointments.

TIPM (Totally Integrated Power Module) Electrical Problems:

• Electrical Command Center Failures: The TIPM acts as a command center for all electrical functions in Chrysler vehicles, and it's notoriously problematic across the entire Fiat-Chrysler lineup. TIPM failures cause a wide array of electrical gremlins including fuel pump not activating preventing engine starting, wipers operating on their own without input, windows not working or operating randomly, horn honking by itself, headlights or interior lights malfunctioning, and dashboard warning lights illuminating incorrectly. TIPM issues were particularly severe in earlier models though they've been somewhat improved in recent production. Replacement TIPMs cost £400-£800 depending on model and availability.

Paint Bubbling and Peeling (2017 Pacifica) - Cosmetic Nightmare:

• Premature Paint Failure: One of the most reported 2017 Chrysler Pacifica problems is faulty paint that bubbles and prematurely peels off, exposing bare metal surfaces that quickly develop rust. This typically happens at relatively low mileage around 34,000 miles on vehicles only 2-3 years old. Owners have been understandably frustrated seeing their fairly new Pacificas already peeling and rusting. Damage commonly starts around the bonnet and spreads across panels. A new paint job resolves the issue but costs £1,500-£3,000 depending on extent of damage and where work is performed. Some owners report that dealerships covered repairs under goodwill though coverage varies significantly. Later model years don't appear to have this issue to the same extent suggesting paint process improvements.

Power Sliding Door Failures (Pacifica and Voyager):

• Door Malfunctions: The power sliding doors that make minivans practical for families frequently fail on Pacifica and Voyager. Doors fail to open or close properly even when using the key fob or interior buttons. Doors get stuck mid-operation creating safety hazards. Sensors malfunction causing doors to reverse unexpectedly. Motor failures require replacement of entire door mechanisms. Wiring harness damage in the flexible section between body and door causes intermittent problems. Repair costs range from £300-£1,200 depending on whether sensors, motors, or complete mechanisms need replacement. Regular lubrication of door tracks helps prevent some issues but doesn't address electrical failures.

Multiple Safety Recalls - Ongoing Concerns:

• Side Curtain Airbag Issues: Chrysler has recalled 2020-2025 Pacifica and Voyager vehicles multiple times for side curtain airbag problems. Improperly secured connectors may prevent airbags from deploying in crashes under campaign A8B. Right and left side curtain airbags may have insufficient pressure retention from improperly sealed seams under campaigns 06C, 54C, and 55C. Dealers secure connectors or replace entire airbag assemblies free of charge. These safety-critical recalls should be completed immediately.
• Steering Column Control Module Defects: The 2023-2024 Pacifica and Voyager have been recalled because the steering column control module may not be welded properly, preventing the driver's airbag from deploying in crashes. This violates Federal Motor Vehicle Safety Standard 208 for occupant crash protection. Dealers inspect and replace modules as necessary free of charge. Check your VIN against NHTSA database to verify recall completion status.
• Other Recalls: 2017-2018 Pacifica recalled for sudden loss of steering control due to separation of right front lower control arm ball joint studs from steering knuckles affecting vehicles built November 2017 to March 2018. 2017 Pacifica recalled for overhead seat belt stow clips that can break turning seat belts into projectiles or making them useless in crashes affecting 3,500 vans built February-April 2016. Multiple other recalls for various issues emphasize importance of checking recall status before purchasing used Chrysler vehicles.

Engine Cradle Rust (2004-2008 Pacifica) - Catastrophic Failure:

• Engines Falling Out: A class-action lawsuit was filed alleging 2004-2008 Chrysler Pacifica models have engine cradles that rust so severely the engines can fall out of the vehicles. This affects the older generation Pacifica crossover SUV, not the modern minivan. Severe rust on structural components creates safety hazards. Owners in salt-belt regions where winter road salt accelerates corrosion are particularly affected. If you own or are considering a 2004-2008 Pacifica, thorough underside inspection for rust is essential. This generation Pacifica should generally be avoided due to multiple serious issues.

Additional Common Problems:

• Carbon Buildup (2004-2008 Pacifica): Carbon buildup on valves triggers check engine lights with P0420 error code typically around 130,000 miles. Symptoms include backfiring and hard starting. Combustion chamber cleaning clears carbon and resolves check engine light temporarily but buildup returns over time.
• Seat Wiring Issues (2004-2008 Pacifica): Wiring complications cause seat heaters, power seat memory, and adjustable pedals to malfunction. Static discharge from damaged wires affects seat features. Seats may get stuck preventing adjustment. Abnormal ticking sounds come from driver's seat. Installing updated seat modules resolves issues.
• Air Conditioning Problems (2004 Pacifica): AC issues start with abnormal hissing noise every few seconds and progress to complete AC failure requiring compressor or system component replacement.

Chrysler Reliability Assessment:

Mixed Reliability with Significant Concerns: Chrysler's overall reliability is better than many perceive, ranking 11th out of 32 brands by RepairPal and achieving most reliable domestic American brand status. Average annual repair costs of £608 versus £652 industry average show reasonable ownership costs. The 300 sedan has proven reasonably reliable with RepairPal 3.5/5.0 rating ranked 7th out of 12 full-size cars. However, Consumer Reports ranks Chrysler dead last out of 30 brands for 2025, highlighting the gap between short-term repair costs and long-term dependability. J.D. Power 2025 shows Chrysler among the worst brands with 256+ problems per 100 vehicles.

Pacifica and Voyager Concerns: The Pacifica and Voyager minivans have serious reliability issues particularly for 2017-2018 model years. The 2017 Pacifica accumulated over 1,000 NHTSA complaints and nine recalls making it strongly recommended to avoid. The 2018 model had 889 complaints and 11 recalls. Transmission problems, engine stalling, electrical failures, and paint issues plague early models. A notable turning point came with 2019 showing marked improvement with only 274 complaints and five recalls. The 2020 model achieved Consumer Reports 5/5 reliability rating. When buying used Pacifica, prioritize 2019+ models and verify all recalls completed.

Maintenance Recommendations: Follow Chrysler maintenance schedules strictly. Perform transmission fluid and filter changes at 60,000-mile intervals. Monitor coolant levels regularly on Pacifica models. Address all recalls immediately especially safety-critical airbag and steering recalls. Keep UConnect systems updated with latest software. Inspect electrical systems regularly for TIPM-related issues. When buying used Chrysler vehicles, obtain full service history, verify recall completion status with VIN lookup at NHTSA website, have pre-purchase inspections by qualified mechanics, avoid 2017-2018 Pacifica entirely, and budget for potential transmission repairs on Pacifica/Voyager. Despite issues, Chrysler offers practical family transportation with excellent features when maintained properly and recalls addressed.

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