Hi,

I have a 1997 S40 which i bought about 2 years ago. At the time I had to change the passenger headlight plug as it had melted and become brittle, causing the headlight to only work occasionally. Recently the headlight on same side started to fail again and I have had a look. It appears the new plug has now melted (same as the last one). I know the headlight unit that the plug is connected to has a loose adjustment system which can be moved by hand.

Is the melting plug caused by the headlight plug getting constricted by the moving headlight? Or is it more likely to be an electrical problem?

Has anyone else come across this problem before

Many thanks

David

Are you sure it's a 1997 S40 and not a 1997 S90? I don't think there is a 1997 S40.

There was a problem with the early S40 relating to headlights. I do not have the details myself, but Volvo had a cable available that either replaces the existing one or is added in. Your Volvo dealer should be able to look up the exact details about it. Don't think many people on this forum will know about it, as the early S40 was not available in the US (I'm in New Zealand).

Hope this helps.

Niel,

Thanks for the advice. I'll have a word with the dealer. It seemed a bit strange as it was only affecting the passenger side.

David