Hello again lads. A couple years ago when my headlights would go out, I popped open the hood and gently slapped the fuse box cover. The headlights would come on and I'd drive for months without a problem. Then about a year ago, it started happening again, and my solution was to take out the headlight relay switch and stare at it for a minute, then plug it back in, (thinking re-seating the contacts would solve the problem.)

So now it's acting up again, and staring at it and plugging it back in isn't working so good. Had to pull over on the expressway last night, open the hood and give the fuse box lid a sturdy bang before the lights would come on.

Is it time for a new relay, or is there something to tweek by opening it up?

If I need a new relay, where's the best place to go?

Thanks!

- thumbs

So long as the socket is still good you can likely pop it apart and check for bad solder joints. My bet is that it can be fixed. There are also some electrolytic capacitors that can go bad. Here is a link to a thread where I posted some pictures. The thread was originally about the fuel pump relay but I posted some pictures of the inside of the headlight relay further down.

http://www.matthewsvolvosite.com/chat/phpBB2/viewtopic.php?t=9681

...Lee

Lee,

Thanks for the response. I didn't want to open up this can of worms right now as I drive home from work at night. Besides, my soldering tools are the big clunky things from the '60s.

A few years ago, I screwed up a fuel pump relay on my old Jetta trying to solder something. Anyhow, I visited my local junk yard this morning and pulled a headlight relay from a '93 850. It works (right now), and if it doesn't act up, I'll consider it good deal for $30.

In a couple days I'll open up the old unit and poke around, as I won't be able to resist inspecting.

Thanks Lee.

- thumbs