VOLVO Repair Manual - Table of Content [200] [700] [900]
by www.VLVworld.com - Your Internet VOLVO Part and Accessory Store Since 1997 - All rights reserved
7.1 Rear Lights
7.1.1 Sedan Rear Lights
7.1.2 Station Wagon Rear Lights

Introduction

Here you will find the replacement procedures for the rear lights of the VOLVO 240, 260, 740, 760, 780, 940, 960. All models have basically the same design and the job is easy to do with very basic tools and knowledge. You can find and purchase most of the parts described in this page (and more) in the following catalogue pages from VLVworld.com:

  • 240/260 Rear Lights catalogue
  • 740/760/780 Rear Lights catalogue
  • 940/960/S90/V90 Rear Lights catalogue

  • 7.1.1 Sedan Rear Lights

    The picture shown here is a 740/760 sedan but the procedure is the same for all models. The tail lights on a sedan consist of:

    • 1,2 Tail light assembly and seal
    • 3 Printed Circuit
    • 4,5,6,9 Bulbs and Sockets

    You cannot replace just one lens on those units. A broken lens nessessitates replacing the entire taillight unit, except for the clear backup lens. This lens alone can be purchased separately from a VOLVO dealer and glued on the assembly.


    View and shop for 240/260 tail lights
    View and shop for 740/760/780 tail lights
    View and shop for 940/960/S90 tail lights
    The printed circuit [3] and the bulb sockets [4,5,6,9] can be purchased individually. The circuits get damaged by humidity in a leaky trunk, resulting in anoying faulty contacts. The complete light unit must be removed in order to change the printed circuit. Installation instructions are listed below.
    Replacing Bulbs

    • Open the tail lamp inside cover
    • Twist the bulb socket counterclockwise and remove it
    • Depress the bulb in the bulb holder and turn it counterclockwise to remove
    • Install a new bulb, ensure the bulb holder is aligned correctly when reattaching
    • Test the new bulb to make sure it illuminates
    • Close and fasten the tail lamp inside cover
    Removing the tail light assembly
    • Open the trunk lid and clear the trunk to make space, on the 240/260 remove the spare wheel on the driver side
    • Open the interior cover [8] from within the trunk, by turning the plastic knob, you will see the interior side of the tail light.
    • Unclip the wiring connector from the light unit, by depressing the retaining tab and pulling.
    • Remove the 2 nuts retaining the interior cover using a 10mm socket (not necessary on 240/260)
    • Notice the 5 nuts retaining the unit to the body. Spray the lower nuts with WD40 or a similar oily product to ease the removal. This is important if you will put back the unit on the car, for example when you change the printed circuit only. Very often the mounting stud on the tail light will break when trying to undo a seized nut, spray generously with WD40 before you try it. Use a 10 mm deep socket or a spanner (you should have a 10 mm spanner in the VOLVO tool kit that came with your car). Keep the nuts since the replacement doesn't always come with them.
    • Undo the screw where the ground wire is fixed to the body with a + screw driver or 10 mm socket depending on the model.
    • Remove the electrical connector from the corner light
    • Carefully slide the whole unit rearwards. Be carefull not to damage the seal if you must re-use it. Most of the replacement tail lights we sell include a new seal. If the car was repainted the seal may be glued on with the paint, remove carefully !
    • Installation of the new unit is the reverse of removal. I like to put grease on the studs to prevent the nut from seizing if I ever need to take it off again, for example to have the car painted later in its life.

    Replacing the printed circuit

    • To remove the printed circuit[3], with the unit removed, carefully pry up the edges of the circuit and detach it from the plastic housing. Locating pins go through the circuit to retain it.

    License Plate Light Removal
    (Part Number 3518672)
    • The lisence plate lights are usually replaced because they no longer hold on the car and are hanging in the wind. This is caused either by someone who pulled on it the wrong way to fix a bulb or the retaining metal springs have rusted off. In the last case make sure that the body of the car around the opening is not too rusted to the point where the hole is bigger than normal, otherwise the new light wont hold either.
    • Grasp the light unit [7] as in the top picture, with your fingers on the side closest to the trunk.
    • Unclip the unit by sliding/pulling rearwards and lowering the side closest to the trunk.Make sure you dont bend the retaining metal tabs located on the outer edge, closest to you.
    • Detach the wire(s) and install the new light. Use grease around the opening to prevent rust, clean the excess with a rag once it is installed.

    Part Number 3518672

    7.3.2 StationWagon Rear Lights

    The picture shown here is for 740, 760, 940, 960 models but the procedure is the same for the other models. A broken lens necessitates replacing the entire unit. The bulb sockets can be purchased individually (see sedan section).


    View and shop for 240/260 wagon tail lights
    View and shop for 740/760 wagon tail lights
    View and shop for 940/960/V90 wagon tail lights
    Replacing Bulbs
    • Remove the interior light cover with a screwdriver
    • Twist the bulb socket counterclockwise and remove it
    • Depress the bulb in the bulb holder and turn it counterclockwise to remove
    • Install a new bulb, ensure the bulb holder is aligned correctly when reattaching
    • Test the new bulb to make sure it illuminates
    • Close the tail lamp inside cover

    Rear Light Cluster Removal
    • 200 Series: remove the side and floor panels to access the tail light from inside. Use a flat putty knife and release the holding clips one at a time, gently prying the panel edge. Remove the spare tire if you are working on the driver side.
    • 700 and 900 Series: Pry off the interior plastic access panel cover with a flat screw driver on the lower edge. You can also remove the floor cover and push the access panel out from behind with your finger.
    • Undo the 10 mm nuts from the studs (see picture). A deep 10mm socket works best. There are 2 or 3 studs depending on the model. Make sure all ligths are turned off to avoid a short circuit. Turn off the car. On the lower nuts use plenty of WD40 if you intend to put back the same unit on the car, the studs too often break when undoing a seized nut. Keep the 10 mm nuts since replacement units do not always come with them.
    • Note the wiring to each socket
    • Slowly pull the light unit away from the vehicle, taking care not to damage the seal between the unit and body, if the replacement doesnt come with a new one (most tail lights we sell come with the seal)
    • Disconect the wires one by one and reconnect them to the new tail light. Otherwise take note of where each wire color is connected before disconnecting the first wire !
    • Attach the new unit to the vehicle in the reverse order.
     

    Number (1) is the stock tail light for 1995 to 1998 960 and V90. Check out these aftermarket clear lens tail lights to customize your volvo (2,3). Not legal in all states, check with local authorities, we disclaim any responsiblitiy.

    Click here to purchase the part(s) shown


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