hi everyone, Well it finally happen after trouble with rear lights I find myself in need of a relay and circuit board. have no rear brake lights all 3. does anyone have spare to sell and where can I get board. used meter to test for power on brakes no power when pressed. went to relay found burn circuit. also board pitted and torn at contacts. also having problem with start switch only start when starter jumped. has this happen to anyone and what did you find. trying to keep it running, thanks for any help. specially ART BENSTEIN..

Hi popdaddy,

Reads like you have simultaneous issues.

What year 240? How many miles?

Dave Barton and others offer new bulb failure sensors (not a relay, though has relays inside it). Though if you can solder, you can open the can be removing the cover and bypass the bulb failure (or bulb out) sensor here:

http://www.240turbo.com/volvorelays.html#bulbfailuresensor

I guess you are in VA-state? Do you have auto salvage yards with Volvo 240 in them? You may get lucky and find a sedan tail light flexi circuit board. I'll guess you have the six panel wrap around tail lights of the early 1980s+. The tail lights vary as to whether you have the third brake light, and you do. With the third brake light is a dual filament bulb holder for the lower outer red lens brake light. On sedans, the white dual filament bulb holder goes to the right side outer, lower most brake light position, and the black dual filament bulb holder goes to the right.

Moisture and placing bulbs and bulb holder incorrectly can ruin the circuit board.

Many examples of direct wiring of the tail light bulb holders to some fixture at the wire harness connector. Wiring diagrams are available so yuou can solder the tail lights for direct and relaible connection.

You can also by the flexi circuit boards.

https://shop.advanceautoparts.com/find/volvo-240-tail-lamp-circuit-board

Other places like Rock Auto, iPd, FCP Euro, and other have these for sale.

After-market at Amazon for both pair of flex tail light circuit boards with dual filament brake lights for use with 240s with third high center brake light.

As for your ignition switch problems ... Automatic or Manual Transmission? Neutral safety switch if automatic? The starter solenoid is okay?

Do you use an excessively heavy key chain in the Volvo ignition switch? Don't. I have one key chain for use in my three 240s that has only the 240 keys and a Volvo keyfob. Though if you have ignition switch wear other minor symptoms usually appears before the ignition switch fails.
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Fyi - the early 80’s naturally aspirated 4 cyl cars had 5 panel lights without the printed circuits. At least that’s how my 82 was. Some of the 6 cylinder and higher optioned turbo cars had 6 panels.
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82 242-6.2L; '17 Mazda3; '16 Crosstrek

the year 89 sedan and I want to hardwire the lights, have looked it up and it look straight forward except the tabs on the brake socket. videos I saw said there were two tabs on each socket but I have founded 3 on these, how are these wired. the yellow/gray wire supply power does this one needs to be pigtail to that wire one for running???? also the 2 black wires and 2 white what do connect to. if you have a diagram of wiring that would great. as for starter I installed push bottom jumper on dash.

I would use a test light or volt meter to ID each wire - brake light, turn signal, tail lights, parking — and wire accordingly.- then be sure grounds are correct.
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82 242-6.2L; '17 Mazda3; '16 Crosstrek

thanks for the help mike but if you have hard wired yours, it would be sensible to look at yours and inform what sockets and color wires was connected EX. {red to running, green to direction, yellow/gray to brake ECT.ECT.} I'm going to assume the red wire will have to be pigtailed, one at the brake socket and jumped to the other side of the assemble running light hence the 3TH spade on brake socket. after further study I would say that the 2 black wires connect to the backup lighting left and right. also the white wires are fog lights only. on passenger side black wire backup, blue directional, yellow brake, brown running, and white fog. if this is the case you message me or if anyone else have this info email...thanks

1989 sedan tail light connections

Left:
Black - reverse
Red - brake
White - fog
Green - turn

Right:
Black - reverse
Brown - brake
White - fog
Blue - turn

Center:
Blue/black - brake
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Art Benstein near Baltimore

"It's been one of those days. Morning DJ moved to the afternoon. Busted a manifold flange stud. Filter slipped from my fingers into the bucket."

I also hard wired in 2 more brake lights on each side so a total of 6 panels light up when the brake switch is closed. I’m not certain my wiring harness (82) is the same color as yours hence my counsel to test first. I’d use Art’s guide to test yours before you wire.
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82 242-6.2L; '17 Mazda3; '16 Crosstrek

thanks for help. I have got a sensor from 91 740 to replace, checked fuse# 7 has power 12.8v. next thing it seems I need to check is input/output at switch
on pedal, what color wires are these?? seen your post Art with pics on this switch but at this time can't remember colors. will check connects there for corrosion first. another though does the right and left side power run on separate sides of car from this switch or both on one side of car if I need to trace?

I would use a test light or volt meter to ID each wire - brake light, turn signal, tail lights, parking — and wire accordingly.- then be sure
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82 242-6.2L; '17 Mazda3; '16 Crosstrek

Many of us have bypassed the printed boards and hard wired the bulbs. That way you avoid the printed circuits altogether.