hi sages- have some thoughts on this issue which i submit to your avuncular scrutiny. i think some reverse engineering is needed here. take alook at thefacts: these newer non sealed beam type headlights in modern tanks are poor on all counts, expensive to replace , difficult to find lenses, less light thrown, etc. one nice thing about the very effective sealed beam, was the glass face rarely went opaque and if it did you would simply replace them from any auto parts store which was cheap. heres my thought- been in plenty of yards and see older junks with fully intact sealed beam assemblies and cover panels which i think could easily be adapted or retrofitted to these so called modern headlights by a diy shadetree mechanic. my 88 buick bohemian has glass lens boxes which is a little better than my saturn and volvo plastic boxes. my 76 duster with sealed beams throws a longer and brighter beam of light down the road than the volvo 240, buick or the saturn. only possible problems i see are politics at the inspection station in those states having inspection and the tsk tsk reaction by purists at a volvo convention. does my hypothesis hold water?(figuratively that is). thanks tons oldduke

I just went through the nightmare headlights scenario with my re3cently-acquired 240. Lenses weren't as yellow as many I see in parking lots on other cars, but were plenty opaque enough almost to kill us on our first mountain night drive home this winter. I thought I'd try new lenses, and found them on ebay at swedish*auto*lamps*for*less
- item number 360585244203. They were $22 each including shipping. I took out the light units, carefully pried off the lenses, checked the reflectors for clean, (one was slightly pitted.) There was also some condensation inside one lens, even though there's a vent at the top of the unit. So fitted the new lenses using silicone RV.
Lights are now a WHOLE lot better. I was saving hi-output bulbs and even considering installing a relay up front to direct-feed the hi beams, but the simple lens replacement was satisfactory. Thank you, Thor! :-) There was and still is) about a 1.2V voltage drop twixt bat + and hi beam wires at the sockets, but they're good enough now for these old eyes! There wasn't a huge apparent difference in the outward look of the lenses, but I guess 22 years took its toll on the transparency.
Good luck with yours!
ps

I can send you one, genuine Volvo, in excellent condition. A friend has some in stock, he deals in used 240 parts, but is not online. If interested send me an email and I'll quote you a price, which you will be happy with.
bikeguy (at) fastmail (dot) fm

It may be a difficult find, but I would look for a used one in a boneyard. You might get lucky as I did and find one that had been replaced with a newer one.

What parts do you need? I may have some laying around.

There is always your local PNP.