Volvo Repair: 1990 740GL troubles, pic n pull, engine mechanic


Question
I hope you can steer me in the right area.  The other day I was driving my car and all was fine except that the headlight which just had a new bulb put in it about 2 months ago was really dim.  Yesterday, I went out and things were fine in the morning but in the afternoon, after I had put the windows down in the car, all of a sudden then the electric windows would not work nor did the turn signals.  I looked under the hood later that night when I got home only to find that the bulb that was just replaced was no longer in the housing of the headlamp.  Needless to say, everything was actually melted.  The headlamp plastic backing was melted as well as the bulb which had fallen out and was laying downward away from it's housing.

I do have a manual for I think up to 1989 volvo so I did alot of reading.  I was trying to diagnos what went wrong since I had already checked the fuses and even though they were fine, I still replaced both fuses for the windows (I think) as well as the fuse for the turn signals.  Still no success.  So upon reading about the relays, the book said that if the emergency flashers worked but the turn signals didn't then it would not be a problem with the relay.

My son and I went to a pic n pull place today and was going to get another headlamp but I discussed the situation with someone who said they worked on cars and he said that what is happening is that I am experiencing a "running" electrical problem which might have originated with the bulb for the headlamp.  Perhaps that is why even when the new bulb was put in, it didn't shine bright like the other light.

Is there anything you can suggest for me to do?  I am a bit mechanical being a jet engine mechanic in the AF many moons ago and still attempt to dabble in my own work on the car.

Is there any direction you can lead me before I end up having to go through expensive car repairs which I can't afford?

I appreciate your time and attention.

Karen

Answer
Karen, thats what I wanted to be when I was in the Air Force but they stuck me in the sheet metal shop.  Oh well, AIr Force needs come first I guess.  From what you are telling me, it sounds like you are having issues with the electrical portion of the ignition switch.  Quick test is to start the car and then turn the key back a little and see if the windows work.  If they do, thats the problem.  If not we need to investigate further.  The black wire on the bulb plug is usually the culprit for a dim bulb.  Since the housing is melted, replace the lamp assembly.  Any other questions, let me know. Roger