I've got an interesting issue going on. I've got a '92 240 Wagon with a 5-speed and my headlights started turning off during my drive home of 40 minutes. I could get the headlights to come back on sometimes by flicking the high beam switch. However, the high-beam indicator in the dash wouldn't come on when switching the high-beam switch. I got a Universal relay for Volvos at an import discount part place but it was a single pole double throw. It would work sometimes, but it was like I had to prime the relay by using the high-beam switch 3 times and then the headlights would come on and stay on. Then that method seemed to crap out and I decided to check the step relay by the battery. I was in need of headlights, so I popped the hood and just put a little pressure on the two connectors on the step relay and presto! The headlights would come on. But, they wouldn't come on the next time without applying some pressure to the relay connectors under the hood. The relay still switches, you can feel it and hear it, however, the high beam indicator on the dash doesn't come on. I've ordered a step relay now that will be in Monday, but is this my true issue?

I did remove the remove the relay and connectors and clean connectors and prongs but after putting it back in, no luck, although it still switches when the high-beam switch is used. Any ideas or clues would be helpful.

Thanks,
Lex

 

I replaced the hi-low step relay with one from a salvaged Volvo and presto, light system issue is fixed. Just was strange how it played out.

 

Was bad wire connection at a relay plug behind controls console below radio

 

The step relay can result in strange problems. I kept getting one bulb out. I replaced the bulb with a new one. Then the new bulb went out. I don't remember then being wired separately, but since I knew the problem was not the bulb I opened up the step relay and found that it has a mechanical lever that "steps" the contacts from low beam to high beam. There seemed to be too much friction to get the relay to fully shift. I found a used step relay, installed it and the problem was solved.