Shipping car parts presents unique challenges. Irregular shapes, fragile electronics, hazardous materials regulations, and carrier selection can quickly become overwhelming.
Whether you’re a restoration enthusiast, mechanic, or ecommerce auto parts seller, you need a reliable process to ship components safely and cost-effectively.
This comprehensive guide breaks down the entire process into actionable steps. You’ll learn exactly what you need to know about packaging techniques, carrier selection, and shipping regulations to get your automotive parts delivered on time and undamaged.
For simplicity, we’ve split this guide into three parts:
01
Quick 15-point checklist—Start here if you have the basics down but need that final confirmation for peace of mind.
02
Brief overview of the crucial steps—e.g., packaging, transport options, and choosing a carrier (with links to an in-depth analysis of each step).
03
Detailed analysis of the 10 steps of shipping parts—a broad bird’s-eye view of all the details.
TL:DR:
Key takeaways
The cheapest way to ship a car part is by standard ground transport.
The fastest way to ship a car part is by expedited air shipping.
Bigger parts might exceed size limits for parcel shipping.
A critical first step is to determine if your car part is hazardous.
PRO TIP: Don’t let auto parts shipping slow down your ecommerce business. As specialists in big, bulky, and heavy fulfillment, we protect everything from sensors to engine blocks with expert packaging and exclusive carrier rates. Get your personalized quote from Red Stag Fulfillment today.
Key steps: packaging, boxing, and choosing a carrier
These three steps are the key to shipping car parts safely and economically. So here’s the least you need to know about them. (Additional insights are found in the 10-step guide below.)
Package auto parts with shipping in mind
Proper packaging comes down to the following:
- Choosing the correct materials.
This might be a foam sheet to protect the paint or anti-static cardboard for electronic components. - Selecting the correct container/box.
This step is about finding the balance between protection and shipping costs. - Placing proper padding between the auto part and the container.
You want to protect the part from transit damage but avoid shifting inside the container.
Choose the right container/box
You want a container that meets the following criteria:
It’s sturdy enough to protect against bumps and knocks in transit.
It can support the part’s weight without bending significantly.
It’s the right size and shape to allow for padding without leaving too much empty space.
It meets any applicable rules and regulations–such as those related to hazardous materials like batteries.
Select a suitable carrier
Key considerations when choosing a carrier are reputation and expertise, speed, costs, safety and reliability, transport options, and coverage.
How to ship car parts in 10 easy steps—a detailed guide
The average car comprises over 30,000 parts, which vary dramatically in terms of size, shape, weight, fragility, and more. So there are no hard and fast rules to cover all car-part scenarios.
But we’ll eat the proverbial elephant one bite at a time.
We’ll break down the process of shipping car parts into 10 steps, all of which are based on the following five overarching principles.
01
Minimize the risk of your part getting damaged by other packages, accidental knocks, or the elements (like moisture).
02
Minimize the risk of your part damaging other packages or, in a worst-case scenario, hurting a handler.
03
Keep the cost under control by understanding the fees and avoiding additional charges.
04
Comply with rules and regulations to avoid shipment rejections or fines.
05
Have fail-safes if something goes wrong. (While optional for some shipments, it’s important for expensive parts.)
While these principles seem simple, they should guide your decisions throughout the following 11 steps.
Measure and weigh the car part.
01
The weight and dimensions of your auto part will directly affect some crucial choices like the box, the transport type, and the specific carrier.
This is especially true in the following three scenarios:
01
The part weighs over 150 pounds.
02
The sum of length and girth exceeds 165” (after packaging).
03
The length exceeds 108”.
PRO TIP: If the car part is too bulky to weigh on a home scale (like a bumper), get creative. Weigh yourself while holding the part and deduct your weight. This will give you the weight of the part.
The weight and dimensions of the packaged part determine if it can be shipped as a parcel.
If it exceeds the limits in the table below, it will be shipped as freight (more on that in a second).
Size limits for shipping auto parts as parcels
| Size limits by carrier | UPS | FedEx | USPS |
|---|---|---|---|
| Length and girth* combined (inches) | 165 | 165 (130 for Express) | 108 (130 for Retail Ground, still charged as oversized) |
| Length (inches) | 108 | 108 | * |
| Weight | 150 | 150 | 70 |
Parcel vs. freight shipping of auto parts
If your car part is shipped as a parcel, it will share a truck with smaller packages–like those housing clothing, shoes, books, etc.
Parcel shipping might be the better choice for lighter car parts (like filters, brake pads, or spark plugs), especially if your shipment is time-sensitive.
How to ship large car parts
Large and heavy car parts will be shipped as freight.
The parts will have minimal contact with other packages (as they’re transported on a pallet or in a separate container).
It might take longer to get them from A to B, but the damage risks are lower.
The illustration below shows items typically shipped as parcels and freight.
Choose the most suitable carrier for your parts.
02
When choosing a carrier, consider the following:
Their expertise, reputation, and experience with auto parts.
Size and weight limits.
Cost of shipping.
Available enhanced shipping options (overnight, express, etc.).
Declared value limits (carrier’s maximum liability).
Comparing shipping costs for smaller parts
For the purposes of this guide, let’s assume you’re shipping a small, relatively light part–something like a truck headlight.
The assumed dimensions (for one headlight) are:
Size of the headlight–24 x 12 x 8”
Size of the boxed package—30 x 18 x 14”
Weight of the package–15 lbs
The shipping math
The sum of length and girth is 84”, so it’s within the size limits and can be shipped as a parcel.
Because it’s a bulky item (for the weight), we’ll calculate the dimensional* and potential billed weight.
Dimensional weight
Dimensional weight is a formula carriers use to account for the item’s volume. For example, a bowling ball might weigh the same as a headlight, but it packs much smaller, so it will be cheaper to ship. Read more about dimensional weight and use our calculator.
Carrier cost comparison for shipping a truck headlight at base rates
The table offers calculated costs for standard shipping per zone, including dimensional and potential billed weight.
| Carrier | Dimensional weight (lbs) | Billed weight (lbs) | Zone 2 | Zone 3 | Zone 4 | Zone 5 | Zone 6 | Zone 7 | Zone 8 |
|---|---|---|---|---|---|---|---|---|---|
| UPS | 55 | 55 | $26.27 | $32.85 | $39.21 | $48.02 | $59.85 | $72.08 | $82.60 |
| FedEx | 55 | 55 | $26.33 | $32.92 | $39.30 | $48.13 | $59.94 | $72.00 | $82.70 |
| USPS | 46 | 46 or 15 | $16.70 | $17.25 | $19.60 | $81.50 | $97.70 | $114.00 | $130.40 |
DISCLAIMER: These calculations are for reference only. They’re calculated for standard shipping at base rates. Use the carrier calculators from UPS, FedEx, and USPS for precise estimates.
Which carrier is most cost-effective for shipping a headlight?
On shorter distances (up to zone 4), UPS will charge less.
Starting with Zone 5, UPS and FedEx are the cheaper options.
Base rates for shipping headlights via UPS and FedEx are almost identical. (The graph lines overlap.)
NOTE: If it’s a bigger part, it will be shipped as freight. Learn more about shipping vs. freight.
Consider choosing a local shipper
It might be cheaper or faster to ship your car parts with a local moving company or smaller carriers.
To do that, follow these steps:
01
Post a detailed job listing on aggregators like uShip.
02
Review the bids.
03
Compare the bids to other carriers–cost vs. speed and reliability.
WARNING: If the part is considered hazardous or restricted, err on the side of caution and choose an established carrier like UPS or FedEx. They likely have more experience handling hazardous materials and a higher capacity to deal with unforeseen situations.
Clean the parts.
03
Before you start packing, clean the parts thoroughly, especially if you’re shipping a used part.
Then, document the “before” condition.
Follow these steps:
01
Use a dry rag to clean debris, grease, and soil.
02
For stubborn dirt, use a water-soluble oil degreaser.
03
Take clear, well-lit photos of the part.
04
If there’s damage, take close-ups and videos to document the details.
NOTE: Photos aren’t perfect evidence—but they’re still valuable. While someone could theoretically stage perfect product photos, then pack damaged goods, visual documentation remains one of your best allies during shipping disputes. If you’re still concerned, ask your carrier where it stands on using photos as evidence.
Gather packaging materials, tools, and supplies.
04
Below is a concise guide to pack and ship auto parts–from the box type/size to the tools and materials you might need.
Reusable vs. one-use containers—examples, pros, and cons
If you’re repeatedly shipping auto parts between the same addresses, consider using reusable containers (e.g., a plastic tote with a locking lid) instead of cardboard boxes.
It might be worth it if you’re an auto parts retailer, a mechanic shop owner, or running a refurbishing facility.
Pros and cons of the two container types
| Reusable container | One-use box | |
|---|---|---|
| Pros |
|
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| Cons |
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Box size
Choosing the correct box size is all-important.
It allows for proper padding, which lowers the risks of damage caused by other packages and accidental drops.
Plus, it stabilizes the part, which translates to a lesser risk of shifting damage.
Rule of thumb: Choose a box that leaves 2 to 3” of space on all sides of the packaged part.
Packaging and padding
Below is a list of tools and materials you might need when shipping car parts.
| Tools | Packaging and padding materials |
|---|---|
|
|
Custom inserts
Custom inserts are a great way to level up your packaging. But they only make financial sense if you’re shipping one part multiple times.
If you’re running a specialized remanufacturing facility, for example, they’re invaluable.
Typically made of recycled cardboard pulp, these are molded to:
Tightly fit the shape of the part.
Snuggly pack into the box.
NOTE: Egg crates are an example of custom-molded packaging. If they can protect eggs in the supply chain, they can protect carburetors.
Package the parts.
05
Proper packaging is the single most critical step on the shipper’s side.
Let’s make sure you get it right.
We’ll start with general guidelines and then get granular in step seven below.
How to pack auto parts—generalized step-by-step guidelines
Assuming you’ve already chosen the proper box, follow these steps:
01
Generously pad any edges and corners, especially any protruding sections.
02
Add a layer of protective foam to fragile or sensitive sections (like glass, fittings, and threads).
03
If it’s a big part that allows simple (dis)assembly, consider taking it apart. Smaller components might be easier to pack and protect. And by packing more parts into a smaller area it might lower shipping costs.
04
If you’re shipping multiple parts in one box, wrap them individually. In this scenario, the biggest risk is damage caused by shifting inside the box, so pad generously.
05
If moisture is a concern (like with electronics), place the part in a waterproof plastic bag before boxing.
06
Pad the bottom of the box with 2 to 3” of bubble wrap.
07
Place the part(s) in the box.
08
Fill the empty spaces to prevent shifting (use air pillows, cutouts of bubble wrap, packing foam, custom inserts, etc.).
09
If needed, print out installation instructions and place them inside the box.
10
Add padding on the top, and close the box.
11
Tape the package securely (more on that in step seven).
12
Consider double-boxing (if it’s a heavy part packed into a one-use container). Add padding between the two boxes to affix the smaller box.
13
Label the box (more details in step eight).
Consider unique challenges related to your specific part.
06
Some parts come with their own unique set of challenges.
Shipping tires and/or rims
Shipping tires and rims require a unique set of guidelines.
Tires only—Technically, you can ship tires without boxing and minimal packaging. As long as the packing slip can be safely secured to the treads, most carriers will accept it. That said, you’ll likely want to include some type of protection—like cardboard sheets, bubble wrap, and cling film—to protect the tire from scuffs and scratches.
Tires with rims—We recommend boxing tires with rims. Without proper packaging, the risk of damaging the rims is higher, and the potential costs of packaging are minor in comparison to the costs associated with damage. The only time to consider foregoing the box is if the box pushes the size over the parcel limits and adds significant surcharges.
Rims only—If you’re only shipping rims, your main concern is scratching. So use the following packing steps
Choose a box that allows for generous padding–no less than 3” on all sides
Wrap the rim in cling film and bubble wrap to prevent scuffing.
Lay padding underneath the rim. Roughly 2.5 to 3” of bubble wrap will do.
Place the wrapped rims into the box.
Add padding to the sides and top to minimize shifting. (Air pillows are a good choice.)
Seal and label the packaged rim.
PRO TIP: Corrugated cardboard is surprisingly abrasive. If you use it, avoid direct contact with sensitive rim parts, like chrome decoration.
Shipping bumpers and hoods
You can ship car bumpers and hoods boxed or unboxed.
The decision will depend on the fragility, value, and condition of the parts.
For both shipping methods, these guidelines apply:
- Take extra care of the paint.
Cover it in layers with cling film or tape, followed by bubble wrap and packing foam sheets. - Take extra care of any corners sticking out.
Use protective foam cushions for extra padding. - Wrap it all tightly using heavy-duty tape.
Double tape if shipping unboxed.
PRO TIP: When shipping bumpers and hoods, consider using no-residue protective tape instead of cling film. It’s just as gentle on the paint but more scratch-resistant. It’s available in different sizes on Amazon.
Shipping a transmission
Shipping a transmission is similar to any part that houses fluids.
The key steps are:
01
Drain the fluid.
02
Pad the transmission with materials that will absorb any leftover fluid (like oil-absorbent pads).
03
Seal it in a heavy-duty bag (in case the fluid leaks).
04
Make sure it doesn’t move inside the packaging. You may need to secure it to a pallet or add nonflexible padding, like molded cardboard inserts, to stabilize it.
PRO TIP: Shipping heavy items like transmissions and similar parts leaves substantial room for costly mistakes. You’re probably better off choosing a professional pack-and-ship service from a carrier like UPS.
Shipping car batteries and other hazmat parts
While car batteries are an obvious candidate for hazmat shipping, you’d probably be surprised by other car parts that are considered hazardous.
Examples include:
Seatbelt pretensioners.
Airbags.
Speakers.
Whole engines.
Struts and shocks.
Some refrigerants.
Fuel system parts.
Stay dampers.
Going into detail about each is beyond the scope of this guide.
What it means for you: Before you start packing, check with your carrier to determine if your part is considered hazardous. If it is, enquire about related packing and shipping requirements.
Seal the packaged parts.
07
For added security, tape the box and double-tape along the center and all edges in an H-pattern.
Label with shipping (and unpacking) in mind.
08
When labeling, go beyond the basic packing slip.
Add custom labels to:
Inform handlers about the nature of the contents (fragile, heavy, hazardous, etc.).
Give handling instructions (this side up, do not stack, keep dry, etc. ).
Provide unpacking instructions. Outline the unpacking steps, print out the list, and affix it to the package. Remember, what’s obvious to you might not be to the recipient.
Stay on top of things with tracking.
09
Use your tracking number to set up daily alerts on the status of your shipment or track the current whereabouts of your parts.
Communicate with the recipient.
10
Share all relevant information with the recipient:
Estimated delivery dates.
Tracking number and ways to check the status.
Unpacking and handling instructions.
Photos and videos of the “before” condition.
Instructions for assembly and installation.
Steps to take if the part arrives damaged.
Clear communication establishes trust, especially if this is the first part they bought from you.
Other considerations when shipping auto parts
Declared value limits
Declared value is the monetary worth you assign to your shipment. It represents the total amount required to replace or repair the item.
The declared value is also the maximum liability of the shipper for lost or damaged car parts.
Most shipping companies offer free coverage for declared values of $100 or less. For higher declared values, you’ll pay a surcharge of 1-2.5% of the package’s worth.
Be realistic when declaring the car part’s value
If problems arise, you’ll need to prove the declared value is accurate.
Proof might come in the form of repair estimates, appraisal reports, purchase receipts, or invoices.
PRO TIP: If you’re shipping an expensive or rare car part, it’s smart to get third-party insurance, which allows for more comprehensive and flexible coverage.
Shipping automotive parts outside the U.S.
Shipping car parts internationally will take longer and require additional documentation.
You might need:
Packing lists.
Commercial and/or Pro-forma invoices.
Custom bonds.
Bill of Lading (BOL)–contract with the carrier.
Certificate of origin and insurance.
Material Safety Data Sheet (MSDS) for hazardous parts like batteries.
Export licences and declaration.
What it all means for you: Plan well ahead if shipping internationally and allow time for delays.
Auto-parts shipping made easy by 3PL expertise
If you’re shipping auto parts in bulk, consider joining forces with a reliable 3PL provider.
Red Stag is an industry leader in shipping heavy and bulky items. We have the know-how, experience, and infrastructure to streamline the process.
For you, this means peace of mind and more time to focus on sales, marketing, and growth. Contact us today to start a conversation about making your life easier.
