I have a quick question I have a 240 dl from 1988 and every now and again the rear passengerside tail light goes out every now and then I did replace the whole assembly except for that white connector that's brittle anyone know of a place to purchase replacement connector

 

I have the same problem, intermittently of course... I've never seen one for sale. Most people actually cut that white pos off and hardwire it to the taillight assembly to solve it. You could go to a junkyard and just grab one from a donor car.

I was actually thinking of (and bought the parts to) make new 8 or 10 pin connectors to replace the white connector and for soldering wires to the control board, and shazam, brand new removable connector.

 

let me look up the PN and see if that connector is still available....

ok, lookee lookee, 'Insulator uncoloured 8-pole' 949543 now, afaik, thats JUST the plastic insulator, NOT the pins that fit inside it, they have seperate part numbers, and the catalog is remarkably useless unless you have one in front of you to visually match.

anyways, the insulator is a $1.50 part from the dealer!! undoubtably special order, and I'd expect most parts counters would want to mark that way up if you're not a regular customer.
https://www.volvopartswebstore.com/p...24/949543.html


now, the contacts that fit in this shell, I'm trying to remember (hey, I fixed a couple of those a dozen years ago but no longer have one to look at), I think those are edge connectors, and there's a bunch of different ones. you'll need to carefully get one out of your broken shell, and see if it looks anything like 35-38 below, and if so, measure A) the width as shown (two different styles, and two different widths), AND B) measure the gauge of the wires that go into the shell (odds are, a couple different gauges...) remember they are metric gauges, which are descirbed as mm2, such as 1.0mm^2... you'll need to find a table that shows how thick metric gauge wires are in 0.01" increments, and use a dial caliber to measure your wires WITHOUT INSULATION. gimme the specificl drawing # and the wire gauge(s) and I can tell you which numbers... like, #36 comes as 979001 for 0.5-1.0 mm^2 wire, and 979002 for 1.0-2.5 mm^2 wire.

oooh, looking at the picture of the connector, it might just be the right angle #26 thats above #31 in this drawing? thats 949542 for 0.5-1.0 mm^2 wires (only size for that style), thats another $1.50 part, https://www.volvopartswebstore.com/p...28/949542.html (but of course, you need like 8 of them or something per taillight assembly)

 

thanks ill buy the pin connector

 

how do you hard wire it in sorry I'm new to both Volvo and wiring

 

ah, those are crimp connectors. you'll need a suitable wire stripper and crimper designed for non-insulated crimps. snip the wires off as close to the old connector as the insulation is good so they are all the same length, strip off the correct amount of insulation from each wire, and crimp the new connector pin things onto the wires, then insert them in the correct order into the insulator and snap the cover over the back. when you trim and crimp them, you want them all lined up the right way so the wires don't have to be twisted to assemble them.

this really isn't that hard to do well, but some practice would be very helpful.