2003-2004 Chrysler 300M & Concorde Radiator Support: Rust, Collision, and Replacement
This guide covers the common failure points of the radiator support, focusing on lower tie bar rust and collision damage for the Chrysler 300M and Concorde.
- The most common failure is not collision damage, but severe rust on the lower radiator support (tie bar), a known issue for these vehicles.
- Replacement is a complex, high-difficulty job (4/5) requiring removal of the front bumper and headlights, and may involve cutting and welding.
- When buying used, you must verify if you are getting the full assembly or just one component, and meticulously check for cracks and rust.
- Driving with a broken support is unsafe as it compromises front-end structural integrity and can lead to secondary failures like radiator leaks.
Symptoms of a Damaged Radiator Support
Failure of the radiator support on a 2003-2004 Chrysler 300M or Concorde is almost always due to two causes: front-end collision damage or rust, particularly on the lower section. The symptoms are typically visual and structural rather than mechanical.
- Poor Panel Alignment: The most common sign is a front end that just doesn't look right. You may notice uneven gaps between the fenders, headlights, and bumper cover.
- Hood Latching Issues: If the hood is difficult to close, won't latch securely, or appears crooked when shut, the upper radiator support that holds the latching mechanism may be bent or broken.
- Visible Damage: After any front-end impact, visually inspect the support for cracks, bends, or broken mounting tabs. The support is made of both metal and plastic components, all of which can be damaged.
- Rattling or Clunking Noises: A loose or broken support can allow the radiator and other components to vibrate, creating unusual noises from the front of the vehicle, especially over bumps.
- Overheating or Coolant Leaks: While the support itself doesn't contain coolant, if it's severely damaged or rusted, it can allow the radiator to shift. This movement can stress and damage the radiator inlet/outlet necks or the hoses, leading to leaks and potential engine overheating.
Known Issues: Lower Support Rust
For owners of the Chrysler 300M and Concorde, especially those in the rust belt, the lower radiator support (also called the lower tie bar) is a major point of failure. This steel crossmember sits low at the front of the vehicle, where it's constantly exposed to water, salt, and road debris. Over time, this leads to severe corrosion.
Forum discussions among owners confirm this is a common problem for the Chrysler LH platform. The rust can become so severe that the lower radiator mounting bushings have nothing left to sit in, leaving the radiator unsecured at the bottom. In many cases, only the lower tie bar needs replacement, not the entire front-end structure.
🎬 Watch: Repairing a rusted lower radiator supportWarning: A severely rusted lower radiator support is a safety concern. It compromises the structural integrity of the front end and can allow the radiator to move, potentially leading to sudden and catastrophic coolant loss.
Buying a Used Radiator Support: What to Check
A used OEM radiator support can be a great value, offering better fitment than cheap aftermarket alternatives. However, a thorough inspection is critical before buying.
- Verify the Correct Assembly: First, determine exactly which part you need. Is it the entire multi-piece assembly, just the upper tie bar, or the commonly rusted lower tie bar? The OEM part number for the lower tie bar is 05003854AH. The side panels are 05003852AD (right) and 05003853AD (left). Confirm with the seller which pieces are included.
- Inspect for Hidden Damage: Look for any signs of a previous accident. Check for small cracks, especially around mounting points for the headlights and radiator. Sight down the length of the support to check for any bends or warping. Even a slightly tweaked support can make aligning panels impossible.
- Check for Previous Repairs: Be wary of supports that show signs of plastic welding or have globs of epoxy. These repairs may not hold up. Look for non-factory welds on metal sections, which could indicate a poorly repaired collision part.
- Assess Rust Carefully: When inspecting a used part, differentiate between surface rust and structural rot. Surface rust can be sanded and painted. However, if the metal is flaking, soft, or has holes, especially around the radiator mounting points, reject the part.
Replacement Overview & Difficulty
Replacing the radiator support on a 2003-2004 Chrysler 300M or Concorde is a complex and time-consuming job. It is not recommended for beginners.
- Difficulty: 4 out of 5
- Estimated Time: 4-6 hours
- DIY Feasible: For experienced mechanics only.
The general process involves significant disassembly of the vehicle's front end, including the front bumper cover, headlights, and hood latch. The cooling system must be drained to remove the radiator hoses. While the A/C condenser is attached to the support, its lines do not need to be disconnected; it can be carefully unbolted and suspended to the side. The support assembly itself is bolted and, in some areas, spot-welded to the vehicle's frame rails. Replacing a rusted lower tie bar often requires cutting the old piece out and welding the new one in for a proper repair.
Pro Tip: While the front end is disassembled, it's the perfect time to replace other wear items like the radiator hoses, thermostat, and serpentine belts. If the radiator shows any signs of corrosion or leaking from the plastic end tanks, replacing it at the same time will save you from doing the job twice.
🎬 Watch: Chrysler Concorde radiator replacement walkthroughCost to Replace Radiator Support (2003-2004 300M & Concorde)
| Part or Service | Estimated Cost |
|---|---|
| New OEM Lower Tie Bar | $190 - $220 |
| New Aftermarket Lower Tie Bar | $90 - $120 |
| Used OEM Assembly | $150 - $350 |
| Shop Labor | $400 - $900 |
| Total Professional Replacement | $500 - $1250+ |
Note: Costs are estimates and can vary based on your location, the specific parts needed (lower bar vs. full assembly), and the extent of any rust repair required. Labor for welding will be higher.
Frequently Asked Questions (FAQ)
Do I have to weld the new radiator support in?
It depends on what you are replacing. The main assembly is primarily bolted to the frame rails, but may have factory spot welds that need to be drilled out and either re-welded or bolted. If you are only replacing a rusted-out lower tie bar, cutting out the old section and welding in the new one is the most robust and recommended repair method.
Can I just replace the lower part of the radiator support?
Yes. Since rust on the lower tie bar is a very common issue, this part is sold separately by both Mopar (Part No. 05003854AH) and aftermarket suppliers. This is often a more cost-effective repair than replacing the entire front support structure if the upper sections are undamaged.
Will a bad radiator support cause my car to overheat?
Indirectly, yes. A broken or rusted support can allow the radiator to move, vibrate, or sag. This can put stress on the plastic inlet and outlet ports or the radiator hoses, causing them to crack and leak coolant. A significant coolant leak will quickly lead to engine overheating.
Are there any recalls on the radiator support for the 300M or Concorde?
No, there are no recalls from the NHTSA for the radiator support on the 2003-2004 Chrysler 300M or Concorde. Failures are typically caused by collision damage or age-related corrosion.
Helpful Videos
Technical Specifications
OEM Part Numbers: 04580065AE (Lower) 05003854AH (Lower Tie Bar) 05003852AD (Right Side Panel) 05003853AD (Left Side Panel) 4580065AD
Multi-piece assembly consisting of upper and lower steel tie bars and side panels. The lower tie bar is the most common failure point due to rust.
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.
- Chrysler 300M:
- Chrysler Concorde: