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A subject that has tormented me for over a year. I'm still working on a halogen or xenon replacement for the earlier (81-85) wedge base bulbs. The biggest problem is heat. Eight months of testing with just higher wattage, tungsten bulbs shows that even with a liner in the bulb cavity, the cluster housing does begin to deform and change color. This is with 5 watt bulbs. I also found that if you do not adhere your "liner" to the inside of the bulb cavity, it will eventually collapse. Thus the only way to make that work, so far, is with a sheet metal liner that can be wedged in place--and that gets very hot too. I have concluded that higher wattage conventional bulbs are not the answer. Eventually I'll find the 3 watt halogen or xenon. LED's, possible solution yes, and I'm testing some with standard-style bases. I think most people don't want to mess with modifying the cluster to accept an LED strip. I want to find one that bayonets right into the hole in the board.
The later style bulbs are in what is called a b10d base. Osram is the primary manufacturer. These are 3 watt halogen bulbs. They are for 89-93 240s only and will not fit the earlier clusters even if you remove the capsule from the base. I've found a slightly lower output replacement for these that's quite reasonable as I was getting bent out of shape with Volvo's pricing for the Osram bulbs, and some sites get as much as $15 each for them. Osram would not agree to let me distribute them in the U.S., unfortunately, as they have an all-powerful agreement with Sylvania. Feedback on the replacements is good so far.
DS
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