Headlights Problems of Volvo S40

Headlight wiring- made an attempt to change light bulbs for headlamps. Covering around electrical wiring harness which connect to headlight crumbled in my hands and electrical wiring is exposed. Worries that this may be potential fire hazard to my vehicle and myself. My vehicle was stationary in my driveway.

See all problems of the 2009 Volvo S40 🔎.

The issue of no headlights (low-bulb failure) is dangerous & expensive. Nor is there a viable permanent repair as the "low-bulb failure" always re-occurs & has been an ongoing problem for me since my car was new. Suddenly having no headlights causes a serious & immediate safety issue for occupants of the car & for oncoming traffic who can't see a car without headlights. It can be 1 headlight or both that fail without warning; leaving no time to bring a vehicle to a stop safely. The experience is frightening & dangerous in those tense moments it takes to stop a moving car on the road without headlights. I have even been issued a violation ticket from the police for equipment failure despite numerous repair bills that I keep in the car. After repeated attempts at getting Volvo to fix this issue, I reported the problem to NHTSA several years ago but was told there had not been enough complaints about the headlight failure problem to do anything. Now, years have gone by and I am still dealing with a car that is essentially a daytime only car as it is not safe to drive after dark due to the unpredictable loss of headlights. Each time the headlights fail I bring the car for service and every time the headlight fails again and again within weeks of the "repair". Repair cost are in the $500 range. There is no recourse for the repairs other than to try something new. It has become a problem that is widely known at repair shops; and aftermarket repair kits are now common because Volvo has ignored the issue stating that there is not a problem to me. It is easy to find many car owners with the same issue and frustrations on the internet as well as suits brought against other auto manufacturers for the wide-scale failure of these useless, defective headlights. Nhtsa should prohibit these headlights and force action for those responsible to address this known safety issue.

See all problems of the 2004 Volvo S40 🔎.

Two different mechanics informed me that the casing in both of my headlights was deteriorating and would need to be replaced.

See all problems of the 2000 Volvo S40 🔎.

The contact owns a 2000 Volvo S40. While driving 65 mph, the engine stalled without warning. The contact was able to pull safely off the road. The dealer stated that the failure was caused by coolant leaking from the engine. The cause of the leakage was unknown. The contact had a maintenance package performed on August 9, 2007 and no failures were found in the engine. The current and failure mileages were 98,000. The consumer stated she expects to be reimbursed the full $3,000 for repairs. The consumer stated upon maintenance repair the passenger side headlight was out and needed to be replaced. Updated 12/12/07.

Types of recurring issues with Volvo S40: headlights, driver front window motor, early brake pad wear. Headlight bulbs were replaced 2-3 times a year at consumer's cost. When brought to the attention of Volvo dealer they reported that it was probably due to lights being used during daylight. They check electrical and reported no issue. Had brake pad and rotor issued shortly after purchasing the vehicle. Volvo dealer reported Volvo rotors were built thin and soft. Cost of brake replacement was not covered under warranty as it was considered regular wear. Driver side window regulator has been replaced three times. First regulator was replaced in June 2005, then February 2006 and now may 2007. May 2007 regulator was at the cost of the consumer as warranty had expired and warranty on part only lasts 12 months even though there is an apparent problem.

See all problems of the 2002 Volvo S40 🔎.

I bought a 2002 Volvo S40 from an individual in January of 2004. In a matter of 3 months in 2005, I had to replace my passenger headlight 3 different times and my driver headlight 2 different times. I called the Volvo dealer and they said that a bulb should last around 2 years. In the next month, my passenger headlight went out again. I got under the hood to replace it as usual. When I pulled the black plastic piece that contains the male part to the wire connection and acts as the bulb socket, it was melted. It was melted to the point that I could not get the bulb out until I used pliers. I took my car to the Volvo dealer and they said that I would have to replace the whole headlight compartment. Since Volvo headlight compartments are "factory sealed", they would not break the seal. I would have to buy a brand new one @ $500. I did not do anything about it, because I am not paying for a whole new headlight compartment for a piece of plastic the size of my thumb. Two days later, the driver side bulb went out and it did the same exact thing, melted. This left me with no headlights! without $1000 to spend on two new headlight compartments (installed), I drove during the day. I found, myself, that the wires (positive and negative) that are connected to the black plastic socket are fairly close together and are not shielded from one another. So, when the wiring harness for the headlights was put together, they did not place the wires nice and neat in there to where there was no way they would touch. When I came to this conclusion, I put black electrical tape around the two wires (positive and negative) in each headlight compartment so that nothing about the wire would touch and obviously had to put new bulbs in. This happened during the second and third week of August 2005. Since, I have not had any problems. I have also replaced both license plates bulbs, the rear fog light bulb, and all four brake lights.

Volvo S40 2002 headlights burned out, replaced 4-5 times. The consumer believed this to be potentially dangerous since the head lights were being used as daytime running lights.

Dealer replaced, in the past two years, headlights/alternator/tail lights, and signal lights, but the problem was still occurring.

The head lights failed.

Headlight burned out for 2nd time in less than 30,000 miles.

With the low beams on, night time visibility is poor and treacherous. I have the same problem with my Volvo 960 which the serviceman states can not be adjusted any better. I hit a deer last week in the S40 and I strongly believe it would not have happened if the headlights were effective. I have owned and driven several cars before including a Mazda miata and a Ford explorer recently and both vehicles have excellent night time headlamp visibility. I strongly believe this is a Volvo design problem. There is greater vsibility to the side than to the front of the vehicle. Please investigate this issue before someone gets seriously hurt.

See all problems of the 2001 Volvo S40 🔎.

Headlights do not throw a beam but rather a spray of dispersed light that lights more of the side of the road than in front of the vehicle. I do not feel safe driving this vehicle at night, especially on narrow dark backroads (which I have to travel frequently). Dealer said they have done everything they can.

2000 S40 purchase new. I have replaced 8-10 headlights already. Vehicle has been costly to maintain. Dealer has taken a minumum of 3 visits to locate problems. None has been resolved completely. Brakes pads replace at 37k- my cost- delar said they wore thin. I have them check the brakes every time I get an oil change - to feel safe. Problems with high pitch whistling noise staring at 60 mph took back several times not able to stop noise before warranty expired. Recently: vehicle ran rough took in to delaer for 90k tune-up. Dealer said bushing on motor mounts are gone cost to replace is $800. Noticed the drivers side power window going out now.

Headlamp buld burned out (12380 miles).

3/6/2007. Volvo S40 2000. Contact has a concern with the brakes and the headlights. The headlights and brakes failed.

Seals on oil line headlight have been replaced numerous times.

Consumer had to replace two rear brake pads after 10230. In addition, headlights burned out and needed to be replaced. Power steering wheel shaft. Ph.