KGM Van Parts UK - Quality Used & Genuine Parts (Formerly SsangYong)

How to Replace KGM Rexton Headlights

KGM Rexton headlight replacement is straightforward and can be completed in 20-30 minutes per side. The Rexton's SUV design provides good access to headlight mounting points.

Step-by-Step Instructions:

1. Open the bonnet and secure it safely. Locate the rear of the headlight assembly from within the engine bay. The Rexton's generous bonnet space provides excellent access to headlight mounting points. On diesel models, the engine sits further back allowing clear headlight access. The seven-seat SUV design means plenty of working room.
2. Disconnect all electrical connectors. KGM Rexton headlights typically have 2-3 electrical connectors depending on specification. These include main beam, dipped beam, and side light connections. On higher-spec Ultimate or Ventura models, there may be additional connectors for advanced lighting features. Press the release tabs carefully and pull straight out to disconnect each connector.
3. Remove the headlight mounting bolts. Most KGM Rexton models use 10mm bolts or Phillips screws to secure the headlight assembly. There are typically 3-4 mounting bolts along the top and side edges accessible from the engine bay. The ladder-frame construction means mounting points are robust and clearly accessible. Remove all mounting bolts completely and keep them organized for refitting.
4. Release any additional clips or retainers. Some Rexton headlights use supplementary plastic clips at the bottom or inner corner for additional security. These clips can become brittle with age, especially on vehicles used for towing or off-road work in harsh conditions. Work carefully to avoid breaking clips during removal.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. KGM Rexton headlights are secured on locating pins that ensure correct alignment. Support the weight as you pull to prevent dropping. The headlight assembly is reasonably heavy due to robust SUV-grade construction.
6. Transfer components to new headlight if needed. If your replacement headlight doesn't include bulbs, transfer these from the old unit. When handling bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as oils cause premature bulb failure. Check bulb type specifications in your owner's manual before ordering replacements.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting pins and push firmly into place ensuring all locating pins engage correctly. Refit all mounting bolts and tighten securely. Reconnect all electrical connections ensuring each clicks firmly into place. Test all lighting functions before closing the bonnet including dipped beam, main beam, side lights, and indicators to verify correct installation and operation.

Important Notes: KGM Rexton headlight replacement is straightforward for most owners. The SUV design provides practical access for maintenance. When handling new headlights, never touch lens or reflector surfaces. Check headlight alignment after fitting using adjustment screws on the rear of the assembly for optimal visibility and safety compliance, particularly important for vehicles used for towing at night.

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How to Replace KGM Musso Front Bumper

Replacing a KGM Musso front bumper is achievable in 60-90 minutes. The Musso's pickup truck construction and ladder-frame chassis means bumper mounting is robust and designed for commercial use and off-road durability.

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 just below the grille area. KGM Musso models have 4-6 bolts or screws securing the bumper to the front panel. These are typically 10mm bolts or Phillips screws depending on model specification. Remove all upper fixings systematically and keep them organized for refitting.
2. Access the wheel arch areas on both sides. Turn the steering wheel fully to one side to maximize access to the wheel arch liner. Behind each front wheel, locate the plastic arch liner. Remove or release 3-5 plastic clips or screws securing the front section of the arch liner to expose side bumper mounting points. KGM uses plastic push-in clips that release by pressing the center pin first. 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 2-3 screws or bolts securing each side of the bumper to the chassis. These are usually 10mm bolts on Musso pickup models. The ladder-frame chassis construction means side mountings are very robust and designed for commercial durability. Remove all side fixings on both sides.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. Locate and remove all screws and clips securing any engine undertray sections and the lower edge of the bumper. KGM Musso typically uses 6-10 fixings along the bottom edge. These may be 10mm bolts or plastic push-in clips depending on model year. The pickup truck design means good ground clearance for underneath access.
5. Disconnect fog lights and electrical connections. Reach behind the bumper and disconnect all electrical connectors including fog lights if fitted and any additional connections for sensors or lights. Press release tabs carefully and pull straight out. Count connections as you disconnect them to ensure correct reconnection during refitting. Musso bumpers typically have fewer electronics than luxury SUVs.
6. Release the bumper from chassis mounting brackets. The KGM Musso's bumper mounts to the ladder-frame chassis via heavy-duty metal brackets designed for commercial use and potential off-road impacts. With all fixings removed, the bumper should pull away from these brackets. You may need to wiggle the bumper slightly to release it from mounting tabs. The commercial-grade construction means Musso bumpers are heavy and robust. A second person is helpful for supporting the bumper during removal.
7. Remove the bumper completely from the vehicle. With all fixings removed and brackets released, carefully pull the bumper straight forward away from the vehicle. Support the bumper properly as Musso bumpers are heavy commercial-duty components built for durability. Place the removed bumper on a protected surface to avoid scratching or damaging the painted surface.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, trim pieces, fog light surrounds, or tow bar mounting points from the old bumper if not fitted to your replacement. The Musso's 3,500kg towing capacity means tow bar integration is common. Align the new bumper with chassis mounting brackets and push into place ensuring all mounting tabs engage correctly with the ladder-frame chassis. Reconnect all electrical connections. Systematically secure with all screws, bolts, and clips in reverse order of removal. Test all electrical functions before final assembly. Check all panel gaps are even on both sides.

Top Tips: KGM Musso bumpers are built for commercial and off-road durability and are heavier than car bumpers. When refitting, ensure tow bar mounting points align correctly as the Musso's 3,500kg towing capability is a key feature. The ladder-frame chassis construction means mounting is very robust but requires proper alignment. Take photos before removal to aid refitting. If your Musso is used for towing, inspect tow bar mounting points for wear or stress during bumper replacement.

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Common KGM Van Parts Problems & Solutions

KGM vehicles (formerly SsangYong until the January 2024 rebrand) are renowned for robust construction and commercial vehicle toughness. The brand offers an industry-leading 5-year or 100,000-mile warranty matching Hyundai. KGM's simple design and construction have earned a following among taxi companies and tow car users for reliable high-mileage service. However, the brand's small UK sales volumes mean limited reliability data is available. Here are the most commonly reported KGM van parts problems based on verified data from UK owners and commercial vehicle specialists.

Parts Availability Issues - Major Problem:

• Extended Wait Times for Parts: The single biggest problem affecting KGM vehicle ownership in the UK is parts availability. Multiple owners report waiting 4-5 weeks for common replacement parts compared to days or at most one week for mainstream brands like Ford, Mercedes, or Vauxhall. The parts network is nothing like what buyers are used to with mainstream manufacturers. Examples include front hub parts requiring 4-5 weeks wait, replacement wheels taking months to arrive even under warranty, and air conditioning pipes requiring weeks of waiting. This extended downtime is particularly problematic for commercial operators who rely on their vehicles for business income.
• Impact on Commercial Operations: For businesses using Musso pickups or Rexton SUVs for commercial work, towing, or taxi operations, weeks of waiting for parts causes significant financial loss. Owners report having to pay hundreds of pounds themselves to hire replacement vehicles while waiting for warranty parts, as no courtesy cars are provided during extended repair periods. This makes the already-affordable KGM vehicles more expensive to operate than anticipated when factoring in downtime costs.
• Limited Dealer Network: With only 73 KGM dealerships across the UK following the rebrand, finding nearby specialist support can be challenging in some regions. While dealers that do exist tend to be smaller family-owned businesses providing pleasant personal service, the limited network means fewer parts stocking locations and longer shipping times for items not held in stock locally.
• Solutions and Workarounds: Plan ahead for servicing and known wear items by ordering parts well in advance. Build relationships with your local KGM dealer to improve parts ordering communication. Consider keeping critical spare parts in stock if you rely on your vehicle for business. When buying used KGM vehicles, factor in potential parts wait times and ensure you have alternative transport available for extended repair periods. Our marketplace connects you with KGM breakers and dismantlers who stock used genuine parts available immediately, bypassing the main dealer parts network entirely.

Warranty Issues:

• Warranty Not Always Honoured: Despite KGM offering a generous 7-year warranty on some models (5-year or 100,000-mile standard warranty), multiple owners report that the warranty apparently counts for nothing as problems are not always covered. Owners describe having to chase customer service repeatedly as promised callbacks never materialize. Combined with no courtesy cars during warranty repairs and extended parts wait times, the warranty experience frustrates owners despite the generous coverage period on paper.
• Recommendations: Document all warranty claims thoroughly with photos and written descriptions. Keep all service records and ensure servicing is performed at authorized KGM workshops or recognized service centres to maintain warranty validity. Escalate warranty disputes in writing and keep copies of all correspondence. The warranty is legally binding despite service issues, so persistence is important.

Engine and Performance Issues:

• White Smoke on Cold Startup: Rexton diesel models sometimes produce loads of white smoke on cold startup that stops after a few miles once the engine warms up. White smoke indicates unburned diesel passing through the cold engine and exhaust, often resulting from low compression in one cylinder, problems with fuel injection timing, or defective fuel injectors. This should be checked by a dealer as it may indicate developing problems rather than normal cold-start behavior.
• Intermittent Power Loss: Rexton RX 270 XDI models can experience intermittent power loss with black smoke and check engine light during driving. This often indicates fuel delivery issues including clogged fuel injectors, faulty fuel pressure regulators, or sensor malfunctions like MAF (mass airflow) or EGR valve problems. Diagnostic scanning is essential to pinpoint fault codes. Common fixes include cleaning or replacing fuel filters, checking EGR valve operation, testing fuel pressure, and inspecting air flow meters.
• Overheating When Towing: The Rexton 2.2-litre diesel engine can overheat when towing at the maximum 3,500kg capacity, particularly on long hills or in hot weather. The trade considers 3,500kg a big ask for the 2.2-litre engine. Owners report suspension sagging and engine overheating when towing heavy loads. Ensure caravan or trailer weight is within legal limits, that the caravan is loaded correctly with no more than 10% of total mass on the tow ball, and consider upgrading to stiffer rear coil springs if regularly towing near maximum capacity. Check coolant system is in good condition before towing heavy loads.

Electrical and Minor Issues:

• Electric Power Steering Pump Failures: Korando models can experience electric power steering pump (EPS) failures requiring replacement. Symptoms include heavy steering, warning lights, or complete loss of power assistance. EPS units can be expensive to replace and may require specialist diagnosis.
• Windscreen Demist Problems: Some owners report windscreen demist systems not working properly, particularly on older models. This can be caused by heater core blockages, blend door actuator failures, or fan motor issues. Proper diagnosis is needed to identify the specific cause.
• Dashboard Display Glitches: Digital displays can experience glitches showing incorrect information or intermittent failures. These electronic issues are not uncommon across all makes and models. Often resolved by software updates or module replacement if under warranty.

Mechanical Reliability:

• Mercedes Engine Legacy: Older Rexton models used Mercedes-sourced diesel engines which are considered sound and reliable. These proven units provide good longevity when properly maintained. Newer KGM-designed engines paired with Hyundai automatic gearboxes are less proven but early reports suggest decent reliability.
• Cracked Cylinder Heads: Some instances of cracked cylinder heads have been reported, often caused by overheating incidents when coolant system problems are not addressed promptly. One owner reported a crack after a broken coolant bottle cap caused overheating and they incorrectly tried to cool the engine with cold water causing thermal shock. Prevention requires monitoring coolant levels, addressing any leaks immediately, and never adding cold water to an overheated engine.
• Fuel System Maintenance: Regular fuel filter changes are important. Some owners report fuel filter warning lights persisting even after filter and water separator replacement, indicating potential sensor issues or incomplete diagnosis. Ensure the fuel system is properly bled after filter changes and that all error codes are properly diagnosed rather than just cleared.

KGM Reliability Assessment:

Limited Data Due to Low Sales Volumes: KGM vehicles are relative rarities in the UK, making it very difficult to unearth consistent reliability patterns. The brand has never appeared in JD Power surveys due to insufficient sample sizes. For the moment, the majority of KGM models on UK roads are still covered by the manufacturer's generous 5-year or 100,000-mile warranty, so any problems can be safely sorted at the supplying dealer, though parts wait times remain a significant issue.

Owner Satisfaction Generally Positive: Despite parts availability frustrations, KGM owners are generally a satisfied bunch when vehicles are working. Owners appreciate the value proposition, 3,500kg towing capability, rugged construction, and spacious interiors. If owners who have posted reviews online are anything to go by, most vehicles have had trouble-free lives once initial issues are resolved. The brand's popularity with taxi companies for high-mileage service and tow car users for reliability when towing heavy loads suggests underlying mechanical robustness.

Simple Robust Construction: KGM vehicles are fairly simple in design and construction without complex electronics, which means less to go wrong mechanically. The ladder-frame chassis used on Rexton and Musso provides exceptional durability for commercial use, off-road work, and heavy towing. Interior materials may look cheap compared to premium brands, but there's no question they're put together well and able to withstand commercial use.

Key Recommendations: Factor in parts availability issues when buying KGM vehicles. Ensure you have alternative transport for extended repair periods. Build a relationship with your local KGM dealer. Use our marketplace to source used genuine parts from breakers immediately rather than waiting weeks for main dealer parts. Keep up with regular maintenance using quality fluids and filters. Don't exceed towing capacity limits, particularly with smaller-engined models. The 5-year warranty provides excellent protection but requires patience when parts are needed.

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