97 Volvo 850 - I usually keep the switch for my headlights on the Daytime Running Light position; last night I cranked the vehicle and I noticed that there were no headlights. Thought I had accidentally turned the switch, but that wasn't the case. Turned the car off, restarted it, and lights came on. Okay ... So I drove to destination, went into the store, came out and cranked car again .. no headlights. Other interior lighting worked, radio worked, door locks, etc. all worked. Stepped on the brakes and I could see from the reflection behind me that both headlights and brake lights were not operating. Turned car off, checked fuses (all looked good), cranked car again and headlights and brake lights came on. I recently lifted the dash board to install an upgraded instrument cluster, and wonder if I may have not connected something or possibly slightly disconnected some cable connector. But before I start pulling dash board up again and checking instrument cluster, thought I'd check to see if anyone has experienced anything similar to this, or where I might best spend my time diagnosing. Thanks for your responses in advance.

It could just be the ignition switch. I have to wiggle the key almost every time I start the car to activate the headlights and turn signal. One day I'm worried it will fail for me altogether.

Ignition switches are reasonably cheap, get a replacement rather than worry. Then take all of the junk off your key chain, which can pull the key out of position when you hit a bump and stall the engine.
--
My name is Klaus and I am a V ♂ lv ♂ holic

So far, a whack under the steering column restores headlights, turn signals and speedometer however it's starting to be a nuisance and I may be going the ignition swap route very soon as well. What all is involved in that? Any tutorials available that anyone know of, pictures are always appreciated.

The only hard part is removing the 4 torx screws that hold the cover to the steering column. Two screws are easy, the other two are recessed about 5 inches. I used a 6 inch extension on my 1/4 inch ratchet and still had a hard time. Some have bought a cheap torx screwdriver and broke most of the handle off to get the shaft long enough. It has been so long, I forgot the size - T10 or T15.

The electrical portion of the switch is on the left had side, two screws hold it in place.
--
My name is Klaus and I am a V ♂ lv ♂ holic

If the ignition switch is changed, do i have to carry 2 keys. One for the starter and one for the doors?

Negative. The electrical part of the ignition switch is what the keyed portion turns and is easily replaced, after you remove the 4 screws that hold the plastic cover around the steering column.
--
My name is Klaus and I am a V ♂ lv ♂ holic

if you look behind your drivers side head light, there is a silver locking arm that connects all your lights to wiring plugs.......sometimes the locking handle comes loose allowing for intermittent light operation.

One other thing... How heavy is your key chain. On the V70R site, someone had a problem with the engine suddenly cutting off... his key chain had a bunch of junk on it and when he hit a bump, the weight caused the key to turn to position I !!!

Klaus
--
My name is Klaus and I am a V ♂ lv ♂ holic

If the ignition switch is not your problem, there was a recall on the headlight switch - if its case is broken, it might feel a little funny.

It is easy to remove it and look at it - the problem is two tabs on the side of the switch break the slots that they go into.

A reasonable temporary (possibly permanent) repair can be made by wrapping the switch case with electrical tape to hold it together.
--
'96 855R,'64 PV544 driver, '67 P1800 basket case, '95 855, '95 854, the first three are mine, heh, heh, 485,000 miles put on 9 bricks

Your description sounds more like an ignition switch problem. Try just moving the key a hair if the lights don't work.

BTW, the DRLs are switched on/off by the fake screw on the outside of the light switch.

Klaus
--
My name is Klaus and I am a V ♂ lv ♂ holic