240 Headlamps

[rustytoba]

Hi all,

As most will probably know 240 headlamp reflectors do lose there lustre, and in time need replacing, however has anyone got some ideas on how to remove the headlamp unit from the front panel, 26 years of inactivity have resulted in nut to stud fusion, no end of WD40 application seemed to help now I appear to have 6 fully rotating headlamp mounting studs.

Any ideas on what to do next would be of great benefit and my appreciation.

Rusty

[Velorum]

Have you had a look at one of Mike Braces archived guides?

http://www.volvoforums.org.uk/showthread.php?t=54565

Must admit I have paid the garage to change mine on previous cars!

[Beetledrive]

The whole units are held on by three nuts/bolts, so once they are off the unit will just slide out. This means you can get the lights out from the back, inside the engine bay, by breaking the nuts off the bolt (requires removing the battery).

I used a shortened hacksaw (which did take a while), but could also be achieved with a drill.

I prefer this method as drilling the bolts out from the front of the car (inside the headlamp unit) can mean that you damage the plastic that holds the bolts, potentially wrecking the headlight units, which can be quite expensive to replace.

[Clifford Pope]

If the nuts are rusted solid onto the studs and the studs turn than the lamp units are already damaged. The ends of the studs are located in hexagonal recesses in the plastic.

Options:
Hacksaw or bolt-cropper or dremel on the nuts/studs
Remove the glass - it is possible to spring the clips from the front - and then drill the stud heads.

Then get new studs and epoxy them into the rounded recesses in the plastic.

[rustytoba]

Many thanks all for the help that certainly did the trick.

Rusty

[Bugjam1999]

Looks like you managed to get the clips holding the glass off from the front- how did you do this? I've got a headlight with a broken reflector mount so I need to get in there... Have had a look at the front and I didnt think there was enough space to undo the clips. Any tips?

I've read Mikes thread before anyone suggests...

Cheers,

S.

[345DL]

A long flat screwdriver will do the job on the clips from the front. You just need to slide it in from the side and twist, and the clip will pop off. Once you get a couple off you get the knack of it. Trouble is, you'll never get them back on again without taking the whole unit off the car.

[rustytoba]

The link to the archive is the key as well as a selection of long thin sturdy slotted screw drivers.

I used the lens as a pivot point and levered the clips off head on a bit risky but needs must as you can see in the pics I chipped the lens where the clip would not give up its grip without a fight, also you'll notice that drilling the heads off the bolts is a bit tricky and can easily get messy but no doubt I'll sort it out and post my pics later on.

I would also point out that in order to remove the black plastic trim between the grille an and the headlamp unit I had to use pliers to turn the screws side on about 90 degrees at a time as the heads where passed it and to be honest the clearance is poor and you cant really get a good enough purchase on the screws with a 'stubby Philips' in that confined area unless the screw heads where really in good nick.

Many thanks to Mike Brace I am his your debt sir.

Rusty

[Bugjam1999]

Cheers all - shall grab a selection of screwdrivers and give it a go... not too worried about the glass since it has a central, medium sized chip in it and I have a replacement to go in.

Cheers,

S.

[CaptainAhab]

Exact thing happened to me mate. Araldite will seat the bolts into the now completely round holes!

Hateful job, I took a dremel grinder thingy to the nuts. Much fun ensued.