The headlight switch on my 1997 965 was replaced a few weeks ago, same symptoms.
Part was $48 plus tax, new Volvo part. From VPI, 713-996-7722. In Houston.
The exact same part from the dealer was $10 more. The switch is also found on 850s. maybe other models too. If you do a junkyard jaunt, get more than one.
Special tools? Two putty knives, both from ACE HArdware. One is 1.5 inch, stiff, chisel tip, ACE SKU 1204924. Theother a 1.25 inch, stiff, not chisel tip, ACE SKU 12731. Total cost about $15.00.
Method: Use chisel tip to pry up the left end of the trim piece covering the switch. It will pry easily. There are pin/clips at the top and the bottom about 2 inches in from the left end. Pry until they come loose. The strip will move slighty to the left and then come farther out.
Push the dash light reheostat in, out of the trim piece. Let it hang back there in back. Then slide the headlight switch to the right a bit, maybe 1/2 inch.
Look in from the left end at the way the headlight switch is attached to the trim piece. I used the non-chisel putty knife as a pry tool to release the trim piece from the bottom of the switch. Use the edge of the tool, not the end.
Once out, swap connectors, and reassemble. The trim piece just pops on. With care there will be no marks showing any work was done.
Good Luck,
Bob
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