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What are the dates of the trail light assemblies? 1992 also? If not, you may, the connection positions where the wire harness secures in the connector that latches to the tail light electrical connection.
Also, from 1987- 88- 89+ or so, you have a dual filament brake light bulb on the lowest, outermost red lens at corner of the tail light. These use a different bulb holder with two +12VDC brass connectors. The bulb holders come in a different orientation unique to side, so, as you stand behind the Volvo 240 looking forward, and inspired by the view, as you own the mighty Volvo 240 in that view, the white dual filament bulb holder goes on the right and the black dual filament bulb holder goes on the left. You 1992 Volvo 240 owner manual makes mention of this in the headlight-bulb section.
If you reverse these, the red lens may deform from the extra heat of the brake light (brighter, hotter) filament illuminated when the running, parking, or position light circuit is on. The fuse won't blow. The heat can cause the reflector body housing to crack along the annealed weld bonding the black ABS reflector plastic to the not entirely compatible red lens plastic material. Some sort of acrylic, I believe. Water then intrudes into the bulb light reflector space, causing corrosion and ruin to the flexible PC circuit board, the light bulb contacts, and possible spurring sheet metal corrosion of the steel there.
I have adapted older, and more durable, incarnations of the final Volvo 240 six panel sedan tail light assemblies to work with the final layout version of the flexible circuit board. It's not impossible. The sedan six-panel tail light housings from a 1982-85 240 are far more durable and fit better. If the six studs used to secure the tail light to the body are fine, use two of the back foam gaskets. Some may also use RTV to help seal and secure the tail lights to the body (rough the plastic up with sandpaper). Some add washers.
The Valeo brand tail lights that came on later 240s do not suffer a high torque of the tail light to sedan body hardware as do all after market tail lights, unless you modify them. The Hella and, I think, Bosch, Volvo 240 six-panel tail lights were much better. I think Valeo is still OEM, or maybe not.
How are the clear plastic headlight lenses doing? Ever grab the bottom center and lift using a finger or two. See how the lens pulls away from the reflector body? You'll need to service the light by cleaning and adhering the lenses to the reflector body. Water intrusion with an illuminated and hot headlamp can cause the bulb to explode, ruining the reflector and lens. You best choice, is then, OEM replacement. The after market headlights are made slightly better than the after market tail lights depending on manufacturing country.
Hope that helps.
Mr. Typey
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