My wife's 93 240 developed flickering headlights a while back and I have been trying to fix it.

My exam of the headlight relay behind the center console just below the AC vents showed a discoloration and melting of the white plastic on the 30 wire at the relay.

I unplugged the relay and pluged it back in. Flickering ended but the relay (especially the 30 terminal) gets hot after 5-10 minutes with the low beams on. No more melting plastic smell though, but still plenty warm. Is this Normal? Tollerable?

I just dropped $35 at the local Volvo dealer for a new relay. It's the one that is 2 X 15 amps (different from the 1 x 30 amp unit I got at the junkyard on Saturday morning). I plugged the new one in hoping to cure everything.

After about 10-15 minutes of driving with the lights on, the new relay gets nice and warm too. Not quite hot to the touch, but definitely warm. Should I keep looking for another problem? or button it up and know that warm/hot headlight relays are OK?

p.s. - tag light bulbs are not working (appear to blow everytime I replace them) but I think these are two separate issues.

thnx.

Don in NE FL