Hello Everyone,

About a week ago, I noticed that all of the warning lights along the bottom of my Volvo’s (1988 740 GLE Wagon) instrument panel were flickering--see post at http://www.brickboard.com/RWD/index.htm?id=927677

I parked the car and pulled the panel out just enough to feel for any disconnected wires, but found none. After this effort, the instrument panel went completely dead, except for the clock.

I resumed driving, and within 20 minutes, the car started to lose power. Fortunately, I was near a Wal-Mart where I purchased a battery to have enough power to get home. The next day I took the car to my local parts store. They checked the alternator and discovered that it wasn’t charging the battery. However, after replacing the alternator, the problem persisted. The battery was still not charging, and the instrument panel was still dead.

A few days later, I followed the suggestion of a Brickboard member who had experienced a similar problem. I removed the instrument cluster and checked it in detail for any breaks in the flexible circuit board. On the back of the cluster right behind the speedometer, there is an exposed part of the circuit about a 1/4" long. I discovered that this exposed part of the circuit had broken.

After rigging a wire to complete the broken circuit, all of the instruments worked. I took the car back to the parts store and had them test if the alternator was charging the battery. It was. The problem seemed solved.

Unfortunately, yesterday, the warning lights along the bottom of the panel started acting up again. I checked my rigged wire, and it’s still in place. The alternator still charges the battery.

When the car is idling, the warning lights in the instrument panel will begin flickering. As I pull away from a stop, the flickering continues until the motor reaches about 2500 rpm--then the flickering will abruptly cease. About 10 seconds later, as I am under power at about 1500 rpm, the flickering will start again. I have to rev the motor up to 2500 rpm to clear the flickering.

It seems that when the car becomes warmed up, or a heavy load is placed on the electrical system, the problem intensifies. Several revs to 3500 rpm are often needed to stop the warning lights flickering.

Recently, I have had difficulties with the car’s headlights, which may offer a clue the cause of the electrical problems.

I noticed in the past few days that the low beam is very dim on the right side and the filaments of both high beams glow, even when the low beams are on. When high beam is engaged, the right side headlights don’t work at all. I have changed the bulbs and the problem persists.

It’s worth noting that about a week or two before any of the difficulties with the instrument cluster began, I had to replace two headlights--a high beam from one side and a low beam from the other side. I have since tested the headlights that I replaced and have discovered that at least one of them works.

Also, within the last day, I have heard a distinct click--almost like a relay engaging--whenever I turn on the headlights. The noise is not coming from the headlight switch itself, but from the region around the fuse panel just in front of the gearshift.

A further clue to the difficulties may be found in the clock within the instrument cluster. Before these difficulties surfaced, the clock didn’t work. Now, it keeps perfect time.

Does anyone have any ideas as to what might be causing the flickering in the instrument panel and the problems with the headlights?

Thanks.

--Megan