Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

6.3

fairly significant
Typical Repair Cost:
$480.00
Average Mileage:
88,488 miles
Total Complaints:
12 complaints

Most Common Solutions:

  1. replace headlight assembly (6 reports)
  2. close air vent hole (1 reports)
  3. electrical tape seals (1 reports)
  4. not sure (1 reports)
  5. replace headlight assembly and ignition switch (1 reports)
  6. replace whole assembly (1 reports)
2004 Toyota Sienna lights problems

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2004 Toyota Sienna Owner Comments

problem #12

Oct 032016

Sienna Xle Limited 3.3L

  • Automatic transmission
  • 74,000 miles

A D V E R T I S E M E N T S

Passenger side headlight assembly has a great deal of condensation inside. From what I've read this is a common problem with 2004 Sienna's and Toyota will not address the problem!!! I want to replace it however at this time the cost is the problem. My Sienna has HID low beam headlamps, can't find an aftermarket lamp assembly! Plenty of halogen lamp assemblies under $200. The cheapest HID assembly I could find is $784 new. Does anyone know if they make an aftermarket HID assembly for a 2004 Sienna?

- , Suffolk, VA, USA

problem #11

May 102005

Sienna XLE 3.3L V6

  • Automatic transmission
  • 93,100 miles

click to see larger images

headlight assembly leaks headlight assembly leaks headlight assembly leaks

I purchased this brand new 2004 Toyota Sienna from a local Toyota dealer in Austin-TX in 2004. After couple months, I noticed water vapor built up (a little bit) on head light; and I brought it to Toyota dealer for attention. They say it is a known issue and the water vapor will be disappeared by itself. They are right and the water vapor disappeared later; but it on and off whenever I drive it on rain for more than 30 minutes.

Last week I had a trip to Houston with 3 hours driving on rain. The water built up significantly (see 1st photo). I felt mad on Toyota and the incapable Toyota dealer technicians, thus I examined it by myself thoroughly. I noticed that on the back of problematic headlight does not have a cap to the vent hole (see 2nd photo). In contrast, the good side has a cap for cover the headlight vent hole (see 3rd photo). This is the Toyota assembly fault and Toyota dealer technicians should know this simple assembly fault. For my layman thought, it must have a crack or hole somewhere on this headlight for moisture to get in. Apparently, Toyota headlight has an air vent hole which plugged with sponge (see 2nd photo) and loosely cap for let air in/out when the air temperature is so different (see 3rd photo).

Suggestion to Toyota, please don't do poor or cheap design on this headlight air ventilation. The cap should be tabbed/screwed for prevent the assembly fault and cap lost.

- , Austin, TX, USA

problem #10

Aug 062014

Sienna LE 3.3L V6

  • Automatic transmission
  • 180,000 miles

Every few months the driver's side headlight would burn out. I started buying multiple bulbs at a time.

Update from Nov 10, 2015: The problem turned out to be the poor design of the seal at the side of the hood. It basically channels all the water to the back of the headlight eventually causing a short circuit and burned out bulb. The fix it to use electrical tape to seal the wiring at the back of the headlight bulb socket. Totally cured the problem.

- , La Crescent, MN, USA

problem #9

Feb 052014

Sienna XLE 3.3L V6

  • Automatic transmission
  • 130,000 miles

A D V E R T I S E M E N T S

Don't understand how water got into the headlight assembly! Bought a halogen light bulb because I thought that was the problem and it costs $99.99. Ridiculous! considering that wasn't even the problem! Thank God AutoZone took it back and gave me my money back. This is an expensive thing to get fixed so my husband found a way to rig up an inexpensive light bulb that blows regularly. We buy these vehicles to keep our children and ourselves safe and pay all this money for the vehicles and Toyota doesn't provide that safeness and security that we demand! It is VERY APPALLING!!!!!!!

- , Birmingham, AL, USA

problem #8

Jun 082012

Sienna LE 3.2L V6

  • Automatic transmission
  • 140,000 miles

It seems this is an assembly defect. Car gas been garage kept. Toyota should provide relief or help for this problem

- , Orange Park, FL, USA

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problem #7

Jul 012011

Sienna XLE Limited AWD 3.3L

  • Automatic transmission
  • 73,000 miles

State inspection will not pass vehicle with moisture in headlight assembly. Service writer tried to tell me this assembly is vented to allow moisture to enter and leave. Further investigation reveals this to be a very large falsehood! He recommended using a hair dryer to dry out the assembly before taking it for inspection! I suspect assembly could be sealed if I can get it out of vehicle where I can find the leak. Suspect it just needs some caulk at the right spot. Will attempt when I have nothing better to do!

- , Mont Alto, PA, USA

problem #6

Jan 032011

Sienna XLE 3.5L

  • Automatic transmission
  • 99,500 miles

A D V E R T I S E M E N T S

click to see larger images

headlight assembly leaks headlight assembly leaks

Since this problem occurred a few weeks ago, I have found that it's quite common for this model to have the headlight assembly crack or whatever and have moisture get in. I have seen people quoted over $1,000 to fix. I was able to get a new assembly (lamps included) from Amazon/Direct Auto for $109 + shipping. However, I have heard that you need to remove the front bumper in order to replace it. I think I'll bring the part to my mechanic to have it installed.

It's unfortunate that Toyota management have been ignoring complaints for years. I had a 2005 Camry with the 6 cyl and 6 spd trans that was nothing but a transmission nightmare. Repeated complaints to the dealer and letter to Toyota did nothing for me, so I sold it to some other unsuspecting schmuck!

- , Canal Winchester, OH, USA

problem #5

Nov 012010

Sienna XLE AWD

  • Automatic transmission
  • 58,409 miles

Bought vehicle at local dealer

Bought Toyota "Extended Care Protection" called "84/120,000 km" COMPREHENSIVE plan for additional $1999

This passenger headlight assembly has leaked in the past...I complained to Toyota..."not our issue"

Now headlamp died...dangerous for driving...took back to same dealer where we have been told to replace the whole assembly ( $1520 plus install, as well as the "ECU" for $1090 plus install)

We have been told the this again does not get covered under our "COMPREHENSIVE TOYOTA EXTENDED CARE PROTECTION PLAN"

What a complete ripoff

- , Vernon, BC, Canada

problem #4

Mar 012010

Sienna XLE 3.2L V6

  • Automatic transmission
  • 42,350 miles

Toyota replaced the assembly a couple of years ago under extended warranty. The problem has now appeared again with the left front assembly. I believe we are no longer under any warranty now, so replacement would be at our expense I would think. But looking at the vehicle, it does not make Toyota look good since this is the second time this problem has occurred..

- , Petaluma, CA, USA

problem #3

May 012008

Sienna LX

  • Automatic transmission
  • 90,000 miles

My headlight assembly and what they call the ignition switch had to be completely replaced at a cost of 1250.00. Now one year later it is broken again. You can see the moisture in there but not how it gets in. I hate to pay to have it replaced again and then just have it burn out again.

- , Edmond, OK, USA

problem #2

Mar 012008

Sienna LE

  • Automatic transmission
  • 49,000 miles

I was even more upset about this after finding out this has happened to several other people with 2004 siennas, and we still have to pay for the fix. Toyota dealership wanted over $450 to fix it, but getting it fixed at different car place for $260.

- , High Point, NC, USA

problem #1

Nov 132006

(reported on)

Sienna CE V6

  • Manual transmission
  • 32,500 miles

Right headlight assembly leaks. This is an inexcusable defect. I work for a Toyota supplier and quality is taken very seriously. This is not a major issue, but definitely an embarrassment. Appears to be an assembly defect.

- , Maryville, TN, USA

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