Find the loose or burnt connection or wire.
No, you haven't missed anything I can think of, but the fact that it was intermittent, then permanent tells me that somewhere therein lies the answer. I admittedly don't know anything at all about "the orange light control relay", but it seems that if that's the problem it would probably affect both sides. Sorry I can't be more help. . .
SOURCE: Left side full beam not woring on SAAB 95 2000
Might as well check the orange headlight control unit first, as it is an extremely common issue, and will only take you 20 minutes. Here is a step by step tutorial with pictures to examine and repair it. The tutorial is from a 1995 900 but is fully applicable to your car.
SOURCE: The drivers side headlight on my 2002 Saab won't
This is probably a problem with the orange headlight relay under the hood in the relay black box. Take the relay out and clean contacts and put back in. If does not fix, try a new relay or swap with another 9-5 to troubleshoot.
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