1999-2004 Tracker & 1999 Sunrunner Headlight Guide: Fixing Haze and Bulb Types
A complete guide to diagnosing, replacing, and buying a used headlight assembly for your 1999-2004 Chevrolet Tracker or 1999 Pontiac Sunrunner.
- The primary failure mode for these headlights is the lens turning yellow and hazy, which severely reduces light output.
- These vehicles use a single, basic halogen assembly with one H4/9003 dual-filament bulb for both low and high beams. No complex electronics are involved.
- When buying a used assembly, the most critical inspection point is the integrity of the plastic mounting tabs. If they are broken, the part is unusable.
- After replacing a headlight assembly, you must perform a headlight aiming procedure to ensure safety and proper road illumination.
Symptoms of a Failing Headlight Assembly
When a headlight assembly fails, it's not always as simple as a burnt-out bulb. The entire housing can degrade, leading to safety issues. Here are the most common signs that your assembly needs attention.
Dim or Yellowed Headlights
The most frequent issue with the headlight assemblies on the 1999-2004 Chevrolet Tracker and 1999 Pontiac Sunrunner is the plastic lens turning yellow, hazy, or cloudy. This is caused by UV damage from the sun, which degrades the outer surface of the plastic. This haze significantly reduces the amount of light that can pass through, making your headlights appear dim at night and reducing your visibility.
Moisture or Condensation Inside the Lens
Finding water droplets or a foggy film inside your headlight lens is a clear sign of a failed seal. While minor condensation can occur naturally with temperature changes and may evaporate on its own, excessive water indicates that the seal between the lens and the housing has broken down. This moisture can cause the reflective chrome surfaces to peel, lead to corrosion on electrical connectors, and may even cause the headlight bulbs to burn out prematurely.
Flickering or Intermittent Headlight Operation
If your headlights flicker or work intermittently, the problem could be a failing headlight relay, a loose connection, or a damaged wire. On some 1999-2004 Tracker models, a wiring harness located under the dashboard near the steering column has been known to get pinched, causing wires to melt together and leading to erratic headlight behavior, such as the high beams turning on by themselves.
Physical Damage
Cracks in the lens or housing from road debris or minor impacts are a serious issue. A cracked lens will allow moisture to enter freely, while a cracked housing can compromise the mounting integrity of the assembly. The plastic mounting tabs that secure the assembly to the vehicle can also become brittle and break, causing the headlight to become loose.
Headlight Technology: Halogen Only
The 1999-2004 Chevrolet Tracker and 1999 Pontiac Sunrunner came from the factory with a single type of headlight: a standard halogen assembly. There were no premium options like HID/Xenon or LED from the manufacturer.
- Bulb Type: These assemblies use one H4 (also known as 9003) dual-filament bulb for both the low and high beams. This single bulb has two filaments inside—one for low beam and one for high beam.
- Simple Design: This is a basic system that does not use any external ballasts, igniters, or LED driver modules. The bulb plugs directly into the vehicle's wiring harness.
Warning: While many companies sell aftermarket LED or HID "plug-and-play" bulbs that fit an H4/9003 socket, using them in a halogen headlight housing is not recommended. The reflector bowl inside the assembly is specifically designed to focus light from a halogen filament. LED and HID light sources are shaped differently, which results in an improper and often illegal beam pattern that creates dangerous glare for oncoming drivers and poor road illumination for you.
Known Issues, Recalls, and Service Bulletins
There are no official NHTSA recalls or major Technical Service Bulletins (TSBs) specifically for the headlight assemblies on these vehicles. However, owners have reported some common electrical problems.
Pinched Wiring Harness
A potential issue has been identified on some Trackers where the main wiring harness under the driver's side dashboard can be pinched against the brake pedal assembly. This can chafe the wires, causing a short circuit that may lead to headlights staying on, fuses blowing, or other strange electrical behavior. If you are experiencing these symptoms, inspecting this harness for damage is a good first step.
Pro Tip: While not a headlight issue, be aware that all 1999-2004 Trackers were subject to a special warranty extension (GM Special Coverage 06186) for severe corrosion on the front suspension crossmember, particularly in salt-belt states. This is a critical safety component, and its condition should be inspected.
Buying a Used Headlight Assembly: What to Check
A used OEM headlight assembly can be a great value, offering better fit and material quality than cheap aftermarket alternatives. However, you must inspect the part carefully before buying.
- Check the Lens Clarity: Look for a clear lens with minimal hazing or yellowing. Light surface haze can often be polished out, but deep yellowing or internal cloudiness cannot.
- Inspect All Mounting Tabs: Carefully check every mounting tab and point on the housing. They should all be present and free of cracks or signs of being repaired with glue or epoxy. Broken tabs are a major red flag, as the headlight will not mount securely.
- Look for Signs of Moisture: Check the inside of the lens for water lines, mineral deposits, or peeling chrome on the reflector. These are all signs that the assembly had a bad seal and will likely leak again.
- Verify the Adjuster Screws: Make sure the manual aiming screws are present and not broken or stripped. Some used parts are sold with missing adjusters, which would make the part useless.
- Confirm Compatibility: Ensure the part is from a 1999-2004 Chevrolet Tracker or 1999 Pontiac Sunrunner. Headlights from the previous generation (pre-1999) will not fit.
Replacement and Aiming Guide
Replacing the headlight assembly is a straightforward job that can be done with basic hand tools. The process involves removing the front grille and a few bolts holding the assembly in place.
Step-by-Step Replacement (Overview)
- Disconnect the Battery: Always disconnect the negative battery terminal before working on any electrical components.
- Remove the Grille: The front grille is typically held on by several clips and/or screws. Carefully remove it to gain access to the headlight assembly's mounting bolts.
- Unbolt the Assembly: Remove the bolts that secure the headlight assembly to the radiator support frame.
- Disconnect the Electrical Connector: Pull the assembly forward slightly and disconnect the main electrical plug from the back of the bulb.
- Install the New Assembly: Installation is the reverse of removal. Connect the new assembly, bolt it into place, and reinstall the grille.
Required: Headlight Aiming After Installation
Anytime you replace a headlight assembly, you must check and adjust the aim. Failure to do so can result in poor visibility and blinding oncoming traffic.
- Park your vehicle on a level surface, 10 to 25 feet away from a flat wall or garage door.
- Turn on your low beams. The top of the most intense part of the beam pattern should be at or just below the height of the center of your headlight bulb.
- Use the adjuster screws on the back of the headlight assembly to move the beam up/down (vertical adjustment) and left/right (horizontal adjustment) until it is properly aimed. The driver's side beam should be aimed slightly lower and to the right to avoid glaring at oncoming drivers.
Cost of Replacement
The cost to replace a headlight assembly can vary significantly based on the type of part you choose.
| Part Type | Estimated Cost (Per Side) | Notes |
|---|---|---|
| New OEM | $250 - $400 | May be difficult to find as the vehicle is out of production. |
| New Aftermarket | $130 - $200 | Widely available from many brands. Quality can vary. |
| Used OEM | $75 - $125 | Good value, but requires careful inspection before purchase. |
| Shop Labor | $75 - $150 | Typically takes 0.5 to 1.0 hours of labor per side. |
Frequently Asked Questions (FAQ)
Is the headlight for the Chevrolet Tracker the same as for the Pontiac Sunrunner?
Yes, for the 1999 model year, the Pontiac Sunrunner was a rebadged version of the Chevrolet Tracker and they share the same headlight assembly. However, the Sunrunner is much rarer, and most parts are listed and sold for the 1999-2004 Chevrolet Tracker.
Do I need to replace the whole assembly if just my bulb is out?
No. If the headlight is simply not lighting up, the first step is to replace the H4/9003 bulb. You only need to replace the entire assembly if the lens is hazy, cracked, or has moisture inside.
Can I install brighter LED bulbs in my stock headlights?
You can, but it is not advisable. The headlight reflectors are engineered for the specific shape and position of a halogen filament. Installing an LED bulb will change the beam pattern, often creating excessive glare for other drivers and potentially reducing your own effective visibility, even if the light appears 'brighter'.
Is it hard to replace the headlight assembly myself?
For most DIY mechanics, this is a relatively easy job. It requires basic hand tools and does not typically require removing the bumper cover. The most critical part of the job is properly aiming the headlights after installation.
Technical Specifications
OEM Part Numbers: 91174687 (Left, Driver Side) 91174685 (Right, Passenger Side)
Bulb Type: H4 / 9003 (Dual-Filament Halogen)
We Have This Part in Stock
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
- Chevrolet Tracker:
- Pontiac Sunrunner:
- 🛍️ Shop This Part
- Symptoms of a Failing Headlight Assembly
- Dim or Yellowed Headlights
- Moisture or Condensation Inside the Lens
- Flickering or Intermittent Headlight Operation
- Physical Damage
- Headlight Technology: Halogen Only
- Known Issues, Recalls, and Service Bulletins
- Pinched Wiring Harness
- Buying a Used Headlight Assembly: What to Check
- Replacement and Aiming Guide
- Step-by-Step Replacement (Overview)
- Required: Headlight Aiming After Installation
- Cost of Replacement
- Frequently Asked Questions (FAQ)
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