2002 Volvo S40 Exterior lighting Problems

“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. …”

“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. …”

“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.”