This is my 2nd 240 wagon. Love it so. But I have had a problem for years with the tail light assemblies. I can get the bulb sockets seated just right and they will work for awhile... then once the warm up they move and disconnect. Pretty much just the brake / running light that's the problem. Both sides... different times. Sometimes they will go off while I'm driving, then back on, then off again.

I bought two brand new aftermarket assemblies and hooked them up. They worked well for a while, then started to blink out. I have even seen the spot where the brake / tail lights insert getting melted from the heat. Once they do, the contact points move and the things are useless.

I've actually gone through two sets of aftermarket lights. I'm having to constantly pull over and tweak the socket - get it to sit right - and hope they stay on until I get home. Got pulled over once, and got a warning.

All of the wires are connected correctly - all contacts are clean. It just seems the little tabs get hot and then start to blink out - randomly. Any ideas? Is it just that the aftermarket parts are not made of the right plastic? Is too much power getting to them? Should I use different bulbs? I'm trying to get the car safe for my son to drive and this is driving me nuts.

If I could find an affordable set of Volvo lights I'd try that - but I'm pretty sure even the original parts went bad too.

 

I have this same problem! The factory 'harness/circuit board' is horrible design. I've been think about cutting it out and installing standard light sockets. Has anyone done that?

 

This has been a long standing problem with Volvos. My 960 and XC90 have similiar issues. A good whack on the light cluster fixes them for a while. The only true fix is to replace the sockets.

 

Where are you getting the aftermarket light assemblies? How long do they last? A year? Five years?

Have you checked out iPd's lights? They usually solve problems like this.

 

Not sure if anyone is still looking for a solution.. LED brake lights will solve the heat issue. They suck as back up lights and don't work in the turn signals but if the problem is mostly brake lights this may be a solution. It won't melt anything at least.

 

try hitting all of the connections with a little WD-40. Everytime I've had problems with blinking lights it fixes it right away and it might help with the heating problem. Volvos have big problems with corrosion, and WD-40 has become my best friend with both of mine.