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Ok, Thanks for all the good advice. I pulled out the relay panel and had a look at the relay. It was fine. No evidence of hot spots or failing connections, etc anywhere on the board in general. All looks healthy. But doing the operational tests that lucid suggested, I noticed that one of the low beams was burned out. It wasn't up until then. So that was the culprit. I put in a new bulb and Voila!, no more BF relay signal. It must have been on the verge of failing all this time and final let go, especially with me poking around at it.
Ah well, at least I know that all the connections, sockets, etc are in good shape on the car.
BTW, the relay panel was much easy to pull out if the cubby hole ABOVE the ashtray is also removed. On my car the wiring bundle was hung up at the back and needed to be lifted over an obstruction to free it up to allow the panel to move forward. Having the cubby hole removed allowed me to reach in and guide the panel and wires out without undue force. To remove the cubby hole, you have to carefully pry off the little cover on the cigarette lighter to get access to a philips screw holding that panel on. Lining up the screw to put it back on was a pain.
Glad I sorted all this out now rather than at -20C in January.
Thanks for all the great advice.
Bill
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Volvo Info Site 1990 745GLE 16valve
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