Every month or so, the drivers side headlight goes out. The routine is the same.... I unplug the bulb and the filament looks fine but there is a brown residue on one side of the connector. I look in the mating harness and it is melted inside on the same side as the brown residue in the bulb connector.
Last night, my son was driving the car home at night and the drivers side headlight went out again and he was pulled over by police I looked at the bulb and harness and the same situation exists as in previous failures.
So, I've got to get to the bottom of this issue and get it fixed more long term.

Any ideas what this could be or how to troubleshoot further?

Thanks.

 

Have you replaced the connector with a Volvo part? There was a bulletin for this and an updated connector was made.

 

I have replaced the connector several times with a connector from Autozone.
Sounds like there is a more robust connector available from Volvo? Could you direct me to where I can this bulletin you refer to?

Thanks.

 

Not sure if it is more robust, but I've never had to replace one twice. The part number is 31294092.

 

$21 at Tascaparts.com (Volvo Dealer that sells genuine parts at a discount...)