Hi,

We have a 1994 940 whose passenger's side headlight produced enough heat to melt part of the plastic housing that holds the lamp securely in place. There's no evidence that there was any sort of electrical short in or around the area, as there are no burn marks on the melted plastic, the headlight still works as it should, and the "light out" indicator on the dash is off. I cannot tell if the plastic melted all at once or if it was done little by little each time the lights were turned on.

For what it's worth, it appears the entire passenger's side headlight unit was replaced before we got the car, as the lens is very clean and clear compared to its driver's side companion, which has turned opaque. The driver's side light and assembly appears fine.

Could this be indicative of a larger elctrical problem with the car?