SsangYong Van Parts UK - Quality Used & Genuine Parts

How to Replace SsangYong Headlights

SsangYong headlight replacement is straightforward on most commercial models. Whether replacing damaged units on your Musso pickup or upgrading headlights on a Rexton Commercial, this guide covers the complete process for all SsangYong commercial vehicles.

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 Musso pickups and Rexton SUVs, the higher bonnet line provides excellent access to headlight mountings. The body-on-frame construction means there's generous space for working. On Korando models, access is more restricted but still manageable with the bonnet fully open.
2. Disconnect all electrical connectors from the headlight. SsangYong headlights typically have 2-3 electrical connectors depending on specification. These include main beam, dipped beam, and side light connections. On models with daytime running lights, there may be an additional connector. Press the release tabs carefully and pull straight out. Handle connectors gently as replacement electrical parts can have longer lead times due to limited UK parts availability.
3. Remove the headlight mounting bolts. Most SsangYong models use 10mm or 13mm bolts to secure the headlight assembly. On Musso and Rexton models, there are typically 3-4 mounting bolts along the top edge and sides, easily accessible once the bonnet is open. Remove all mounting bolts completely and keep them organized. Some models may have additional fixings at the bottom edge requiring underneath access.
4. Release any additional clips or retainers. Some SsangYong headlights use supplementary plastic clips for additional security. On Musso pickups, check for clips at the inner corner near the grille. On Rexton models, look for clips at the outer edge near the wing. Work carefully as clips can become brittle with age, especially on vehicles used in harsh agricultural or commercial environments.
5. Carefully remove the headlight assembly. With all bolts and clips released, gently pull the headlight straight forward out of its mounting position. SsangYong headlights are reasonably substantial on pickup and SUV models, so support the weight as you pull to prevent dropping. If you feel resistance, stop and check for missed fixings rather than forcing. The rugged construction means mounting points are robust but forcing can damage surrounding bodywork.
6. Transfer components to new headlight if needed. If your replacement doesn't include bulbs or adjuster mechanisms, carefully transfer these from the old unit. When handling bulbs, wear clean gloves to avoid touching glass surfaces with bare hands as oils cause premature failure. This is particularly important on commercial vehicles that operate long hours in demanding conditions.
7. Install the new headlight assembly. Reverse the removal process by aligning the new headlight with mounting points 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. Test all lighting functions before final assembly including dipped beam, main beam, side lights, and indicators. Check headlight alignment using adjustment screws on the rear of the assembly for optimal visibility.

Important Notes: SsangYong headlight replacement is achievable in 30-45 minutes on most models. Parts availability can be a challenge for SsangYong vehicles, so sourcing headlights from specialist breakers or our marketplace ensures you find the correct unit for your specific model year. When buying replacement headlights, verify they match your vehicle's specification as SsangYong made running changes throughout production. Proper headlight alignment is crucial for MOT compliance and safety, especially on commercial vehicles operating at night.

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How to Replace SsangYong Front Bumper

Replacing a SsangYong front bumper is achievable in 60-90 minutes depending on model and whether you have parking sensors or fog lights fitted. This process covers Musso, Rexton, Korando Commercial, and Rexton Commercial models, though specific mounting points vary between generations and body styles.

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. Most SsangYong models have 4-6 bolts or screws securing the bumper at the top. On Musso pickups, these are typically 10mm bolts easily accessible from above. On Rexton SUV models, expect 6-8 fixings across the top including some behind the grille. Remove all upper fixings systematically and keep them organized.
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 liner to expose side bumper mounting points. SsangYong uses push-in clips that release by pressing the center pin first, then pulling the outer portion. Repeat on both sides for complete access.
3. Remove the side mounting screws from both wheel arches. Behind each wheel arch liner, you'll find 2-3 bolts or screws securing each side of the bumper to the chassis. These are usually 10mm bolts on SsangYong models. Remove all side fixings on both driver and passenger sides. The body-on-frame construction means these mounting points are very robust. Keep track of which fixings came from which location.
4. Remove undertray screws and lower bumper fixings. Get underneath the vehicle safely using ramps or jack stands. The high ground clearance on Musso and Rexton models makes underneath access easier than on conventional vans. Locate and remove all screws and clips securing any engine undertray and the lower edge of the bumper. SsangYong typically uses 8-12 fixings along the bottom edge. These may be bolts, screws, or plastic push-in clips depending on model year.
5. Disconnect fog lights, sensors, and electrical connections. Reach behind the bumper and disconnect all electrical connectors. This includes fog lights if fitted, parking sensor connections if equipped with parking assist, and any additional connections for daytime running lights on newer models. Press release tabs carefully and pull straight out. Count how many connections you disconnect to ensure you reconnect them all during refitting. Given SsangYong's parts availability challenges, handle connectors with extra care.
6. Release the bumper side clips and mounting tabs. SsangYong bumpers are secured by plastic clips or metal brackets on each side that engage with the wing panels and chassis. 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 Ultra-High-Strength Giga steel construction means mounting points are very secure.
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. SsangYong bumpers are substantial on pickup and SUV models, particularly on Musso and Rexton, so a second person is strongly recommended due to size and weight. Place the removed bumper on a protected surface to avoid scratching the painted surface or damaging any integrated components.
8. Prepare and fit the replacement bumper assembly. Before installation, transfer any brackets, fog light surrounds, towing eye covers, or trim pieces from the old bumper if not fitted to your replacement. Align the new bumper with mounting points and push firmly into place ensuring all side clips engage properly with the chassis and wing panels. Reconnect all electrical connections including fog lights and parking sensors, ensuring each connector clicks firmly. Systematically secure with all screws, bolts, and clips in reverse order of removal. Test all electrical functions including fog lights, parking sensors, and any integrated lighting before final assembly. Check panel gaps are even on both sides and bumper sits flush with wings.

Top Tips: SsangYong bumpers are designed for practical replacement, reflecting the commercial nature of these vehicles. When refitting parking sensors, ensure each clicks firmly into its mounting hole and is correctly aligned flush with the bumper surface. On Musso pickups used for agricultural work, check for mud and debris buildup behind the bumper before fitting the replacement. The body-on-frame construction means bumper mounting points are extremely strong, but check the condition of mounting brackets and replace any damaged components. SsangYong parts can have longer lead times than mainstream brands, so inspect all brackets and clips during removal and order replacements if needed. Check all panel gaps between bumper and wings are even before final tightening.

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Common SsangYong Van Parts Problems & Solutions

SsangYong commercial vehicles are valued for rugged construction and exceptional value. The brand has a VehicleScore reliability rating of 642/999 and consistently ranks highly in the HonestJohn Satisfaction Index. However, certain components can experience specific issues, and parts availability presents the biggest challenge for UK owners. Here are the most commonly reported SsangYong commercial vehicle problems based on verified data from UK owners, mechanics, and industry specialists.

Parts Availability Issues - The Biggest Challenge:

• Extended Wait Times for Parts: The most significant problem facing SsangYong owners is parts availability. Multiple UK owners report waiting 4-5 weeks for parts even under warranty, with some components taking months to arrive. This affects both mechanical parts and body panels. The limited UK dealer network and South Korean supply chain mean parts must often be ordered internationally, leading to extended vehicle downtime particularly frustrating for commercial operators relying on vehicles for business.
• Limited Parts Network: Unlike mainstream manufacturers, SsangYong has a relatively small parts distribution network in the UK. Local independent garages often refuse to work on SsangYong vehicles specifically because they cannot source parts quickly. This forces owners to use main dealers who may also face supply issues. For commercial vehicle operators, this downtime directly impacts business operations and income.
• Solution and Prevention: When buying SsangYong parts, use breakers and specialist suppliers on our marketplace who stock parts immediately available. Build relationships with SsangYong specialists who maintain parts inventory for common failure items. Consider stocking critical wear items like filters, brake components, and common electrical parts before they're needed. When parts fail, order immediately even if vehicle is still drivable to minimize downtime. Budget for hire vehicles during extended repairs as warranty doesn't typically cover business interruption.

Electrical Problems - Infotainment and Battery Issues:

• Touchscreen and Infotainment Failures: A widespread problem affecting multiple SsangYong models is touchscreen and infotainment system failure. Symptoms include touchscreen becoming unresponsive, Bluetooth and CarPlay connectivity failing, radio system malfunctioning, and complete head unit failure. This problem affects many Korando and Rexton models built in recent years. Multiple owners report SsangYong refusing warranty claims on systems despite being within coverage period, claiming system is only covered for 36 months even when vehicle has longer warranty.
• Battery Drain Issues: Several owners report unexplained battery drain problems where battery goes flat within days even after replacement. One long-term test vehicle experienced repeated battery failures that left technicians puzzled, eventually requiring vehicle replacement. Symptoms include battery going flat after short periods of non-use, electrical gremlins appearing randomly, and difficulty identifying root cause. This problem seems more common on Korando models.
• Solutions: For infotainment failures, replacement of the complete head unit is typically required costing several hundred pounds. Used units from breakers offer more affordable alternatives to new dealer units. For battery drain issues, comprehensive electrical system diagnosis is essential to identify parasitic draw. Check for aftermarket accessories drawing power. Replace battery with high-quality unit designed for frequent short journeys if vehicle is used for local commercial work.

Fuel System Problems - Diesel Injector and Delivery Issues:

• Fuel Injector Failures (Rexton 270 XDI): The Rexton 270 XDI model commonly experiences fuel injector problems causing intermittent power loss, black smoke from exhaust, check engine warning light, and rough running. Common causes include clogged fuel injectors from contaminated fuel, faulty fuel pressure regulators affecting delivery, MAF sensor malfunctions causing incorrect fueling, and EGR valve issues affecting combustion. These problems are exacerbated by poor quality diesel and infrequent fuel filter changes.
• Warning Signs and Diagnosis: Symptoms include sudden power loss during driving, black smoke under acceleration, check engine light illuminating, and rough idle or hesitation. The power loss typically recovers after shifting to neutral and driving briefly. Diagnostic scanning reveals fault codes pointing to fuel system components. Regular replacement of fuel filters and water separators prevents contamination reaching expensive injectors.
• Repair and Prevention: Solutions include cleaning or replacing fuel injectors costing several hundred pounds depending on extent of damage, replacing faulty sensors like MAF or fuel pressure regulator, and cleaning EGR valve to restore proper function. Preventative measures include using premium diesel fuel from reputable suppliers, replacing fuel filters every 12,500 miles or annually, draining water separator regularly particularly in winter, and using diesel fuel treatment additives periodically. For commercial vehicles covering high mileage, proactive maintenance prevents expensive failures.

Transmission Issues - Automatic Gearbox Performance:

• Laggy Automatic Gearbox Response: The Mercedes-sourced automatic gearbox used in older Rexton models and the current six-speed automatic in Musso and newer Rexton models are mechanically sound but not the most responsive. Owners report sluggish gear changes, delayed throttle response, and unrefined operation compared to modern dual-clutch or advanced automatic transmissions. While not a fault, the gearbox characteristics take adjustment and suit the vehicles' work-oriented nature rather than sporty driving.
• Manual Gearbox Reliability: The six-speed manual gearbox fitted to Musso and Rexton models has proven reliable with few reported problems. Manual transmission models are often preferred by commercial operators for better control when towing heavy loads or operating off-road. The manual gearbox suits the vehicles' agricultural and commercial applications.
• Recommendations: Automatic gearbox operation improves once drivers adapt to its characteristics and anticipate gear changes. Regular transmission fluid changes extend gearbox life. Use only SsangYong-approved transmission fluid. For towing heavy loads regularly, the manual gearbox offers better control and longevity. If automatic gearbox develops harsh shifting or grinding noises, immediate inspection is essential as repairs can be expensive.

Brake Wear - Faster Than Expected Consumption:

• Rapid Brake Component Wear: Multiple Musso and Rexton owners report that brakes consume faster than expected, particularly brake pads and discs. This likely relates to the vehicles' substantial weight from body-on-frame construction and frequent towing applications in commercial use. Brake pads may need replacement every 15,000-20,000 miles depending on usage versus 25,000-30,000 miles on lighter vehicles.
• Tyre Longevity: Interestingly, while brakes wear quickly, tyres last considerably longer than expected. Many owners report 40,000-50,000 miles from quality tyre sets, significantly exceeding typical pickup truck tyre life. This suggests the Ultra-High-Strength Giga steel construction and suspension geometry minimize tyre scrubbing.
• Solutions: Budget for more frequent brake servicing if using vehicle for heavy towing or loaded commercial work. Upgrade to premium brake pads designed for heavy-duty applications. Have brake system inspected every 10,000 miles to catch wear early. The longer tyre life partially offsets higher brake costs. When replacing tyres, consider premium all-terrain options if vehicle is used off-road regularly, though many owners recommend immediate tyre upgrades as factory-fitted tyres are adequate but not exceptional.

Suspension and Driveline Issues:

• Driveline Shudder and Vibrations: Some Musso owners report driveline shudder or vibrations, particularly on four-wheel-drive models. This can be caused by driveline angle problems from improper suspension modifications, worn universal joints or CV joints, or tailshaft balance issues. If you've fitted aftermarket suspension lifts or modifications, ensure they've been installed correctly with proper alignment and any necessary supplemental parts like tailshaft spacers.
• Harsh Low-Speed Ride Quality: The body-on-frame construction and commercial-grade suspension mean ride quality is firmer than car-based SUVs, particularly when unladen. This is a characteristic rather than a fault, and ride comfort improves significantly when carrying loads or towing. Many commercial operators upgrade to premium aftermarket suspension systems for improved on-road comfort while maintaining towing capability.
• Recommendations: For commercial vehicles, the firm suspension is beneficial for load carrying and towing stability. If you've modified suspension, ensure installation was performed correctly by specialists experienced with body-on-frame vehicles. Regular inspection of driveline components including propshafts, universal joints, and CV joints prevents vibration problems. If shuddering develops after modifications, have driveline angles checked and corrected.

Customer Service and Warranty Concerns:

• Poor Dealer Support and Warranty Claims: A recurring complaint from UK SsangYong owners is poor customer service from both dealers and SsangYong GB. Owners report warranty claims being refused even for covered components, dealers failing to return calls or provide updates, months-long wait times for warranty repairs, and lack of courtesy vehicles during extended repairs. The 5-year/100,000-mile warranty (previously 7-year/150,000-mile) sounds impressive but multiple owners report it's difficult to get claims honored.
• Limited Dealer Network: SsangYong expanded UK dealerships to around 65 locations, taking over some ex-Mitsubishi dealers, but this is still far smaller than mainstream brands. If your local dealer provides poor service, alternatives are limited. The company rebranded to KGM in 2023 following acquisition, but customer service issues appear to continue under new ownership.
• Recommendations: Research local dealer reputation before purchasing. Join SsangYong owner forums and social media groups to identify recommended dealers and specialists. Build relationships with independent specialists experienced with SsangYong vehicles as alternatives to main dealers. Document all communications regarding warranty claims. Consider extended warranty from third-party providers for additional protection, though check coverage carefully. Use our marketplace to source parts from specialist breakers who understand SsangYong vehicles and can provide immediate parts availability.

Build Quality Concerns:

• Interior Materials and Fit: While SsangYong vehicles have tough mechanicals, interior quality uses cheaper plastics particularly on lower dashboard and door cards. Some switches feel cheap though they're generally well-damped. Electric seats can thud to a halt when reaching adjustment limits. These are minor annoyances rather than mechanical faults, but they make the vehicles feel less premium than similarly-priced mainstream alternatives. However, the function-first approach means interiors prove very resilient in commercial use.
• Body Panel Fit and Finish: The Ultra-High-Strength Giga steel construction provides excellent structural integrity and crash protection, but some owners report minor fit and finish issues like panel gaps, trim pieces rattling or coming loose, and paint quality below mainstream standards. These issues don't affect mechanical reliability but can be frustrating on newer vehicles.

SsangYong Reliability Assessment:

Solid Mechanical Reliability with Service Challenges: SsangYong's mechanical reliability is good, with a VehicleScore rating of 642/999 and consistent high rankings in the HonestJohn Satisfaction Index. The brand's Mercedes-sourced engines in older models provide proven reliability, while current 2.2-litre diesel engines are mechanically sound. Body-on-frame construction using Ultra-High-Strength Giga steel means vehicles withstand harsh commercial use. The 5-year/100,000-mile warranty demonstrates manufacturer confidence in build quality. However, the biggest challenges facing owners are parts availability with 4-5 week wait times, poor customer service from dealers and manufacturer, and difficulty getting warranty claims honored despite coverage.

Value Proposition: SsangYong vehicles offer exceptional value compared to mainstream competitors. A Musso provides similar capability to Ford Ranger or Toyota Hilux at significantly lower purchase price, while Rexton offers seven-seat SUV space with 3,500kg towing capacity at a fraction of Land Rover Discovery cost. For buyers prioritizing value and capability over badge prestige, SsangYong vehicles deliver. The vehicles are particularly popular in rural communities and with farmers who value work capability and affordable running costs.

Best Practices for SsangYong Ownership: To maximize reliability and minimize downtime, follow these recommendations. Use our marketplace and specialist breakers to source parts with immediate availability rather than waiting for dealer orders. Build relationships with independent SsangYong specialists for servicing and repairs. Stock common service items and wear components before they're needed. Follow service schedules strictly using quality parts and fluids. For commercial operators, budget for hire vehicles during extended repairs as warranty rarely covers business interruption. Join owner communities to learn from others' experiences and identify recommended specialists. When buying used SsangYong vehicles, prioritize models with full service history and verify warranty status. Despite service challenges, the mechanical reliability and exceptional value make SsangYong vehicles worthwhile for buyers who plan proactively.

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