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1989 765T Headlight Relay question 700 1989

posted by  oopala on  Sat Aug 6 15:07 CST 2005
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last visit: Fri Oct 23 19:40 CST 2009
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1989 Volvo 760 Turbo Intercooled station wagon with automatic transmission.

I'm hoping someone who has had the same troubles I am having might be able to help me out. Here's the scoop: I have been experiencing intermittent headlight failure, i.e., with the rotary headlight switch on, the headlights will turn on about 50 percent of the time. The brights seem to work all the time, and I can flash the brights with the rotary headlight switch in the off position. After unselecting the brights, the dims don't come back on every time...

As per the 700/900 FAQ, I thoroughly cleaned the grounding lugs behind the headlights on both sides and tightened them up. Then I removed the trim panel on the passenger's side and pulled out the relay to check the connections and lugs. I also pulled off the cover of the relay to look for any obvious signs of overheating/loose connections/cracks in the solder with no visible sign of troubles (Whole bottom of relay board is coated with some kind of clear varnish/lacquer stuff). I plugged the relay back in and ran the rotary light switch on and off, and sometimes the dims will not come on, and then 5, 10, 40 seconds later, come on of their own volition; others, the lights come on as normal. I also pulled out the headlight rotary switch and cleaned all the contacts. Man! There are lots of little balls, springs, and dumbbell-shaped rollers inside that switch. I managed to get it all back together again, and same results: the lights have a mind of their own.

I can hear a click from the headlight relay (marked A E) each time I switch to bright headlights, but it doesn't click if the dims are selected and don't come on. I have looked online to find a replacement headlight relay with no luck. fcpgroton, ipdusa.com, vlvworld.com have no relay for my model. Does this sound like the headlight relay is bad? Could I still have a problem with the grounding lugs behind the headlights on the fenders? Any advice? I can't very well drive this car with the headlights going on and off with no input from the driver! How much does this relay cost and can I get it anywhere besides the local bandits at Volvo?

Thank you in advance for your suggestions and help. Keep on Brickin'!

Oopala






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