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Dear penntellect,
Good a.m. and may this find you well. Using the 1993 940 wiring diagram (Volvo Manual TP32208/1), I'd guess the root problem is a weak ground. The change of ignition switches - and the persistence of the problem - suggests the problem is wiring-related. It is unlikely, that you got two faulty replacement ignition siwtches.
A weak ground could result from:
(a) corrosion
(b) a loose connection
(c) damaged insulation or a wire's conductor being broken inside the insulation (the result of the wire being pinched - or having been pinched - when it was caught between two hard objects).
Because there are several problems, there are several places to look. Ground points, for the instrument cluster and related items are:
(a) behind the kick panels on either side of the footwells, just in front of the point, where the front door hinges are attached. When removing the plastic panels, be gentle: plastic gets brittle with age.
(b) inside the engine bay, on the inner fender walls, just behind the headlights
(c) the main electrical distribution block (fuse block), which is behind the fronter center console ashtray.
Ground wires are usually black. Ground contacts can be cleaned with an aerosol de-oxidizer (available from auto supply stores).
You will need a volt-ohm-multimeter, to check for continuity (that the wire is not broken). Set it to "OHMS"( Ω ). You will need someone, to wiggle the wires, while you check them for continuity, so that if there's an break, the movement will reveal it. The meter should read "0" = no resistance, if the wire is in good condition. If the meter reads ∞ = infinitely high resistance, that means the wire is broken.
You could get lucky, and find:
(a) an obviously broken/loose/corroded ground wire
(b) a ground wire, that is pinched (look for indentations in the insulation).
A pinched wire should be replaced, unless you can wiggle it, and it shows no signs of being broken inside the insulation.
Hope this gets you started. Electrical problems require great perseverance. If you persevere, you'll find the fault.
Please post back, with your findings.
Yours faithfully,
spook
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