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Hiya Uncle Marty Oleseahorse!
Oooop, so you need to do more than merely replace the bulbs.
I get a little confused as to what upgrades happen in what years. So, I guess, and wrongly, I guess, that a 1992 Volvo 740 has the glass lens secured to the metal reflector body using clips and an adhesive that can get brittle and lose seal. Like on 940.
Yet I'll guess you have the dual square plastic lens headlight with the plastic reflector bucket (or body). The assembly uses some grey gasket adhesive sealant from the factory that should be quite brittle and lose seal. You may be able to pull on the plastic lens along the bottom corner, or other corner and feel a separation.
In such instance, lens-reflector assembly requires:
- Complete replacement
- Rehab of the assembly, if the factory reflector finish is bright, shiny, and smooth with out indication of de-lamination.
If you can see the reflector is futzed as you describe, probably a replacement of the lens-reflector assembly.
Or, trips to the yunkyard to find replacements or newer upgrades if headlamp assemblies from 940 would fit the mount.
What I'd done several times, and two two of my three current 240s, as someone did the task on the li'l red wee beastie 1990 240 DL wagon is to:
- Pull the hobbled headlamp-turn signal assembly.
- Separate from the turn signal and remove the bright work trim along the top
- Separate the lens from the reflector
- If the reflector is mirror smooth, go ahead ...
- Use a debriding agent like toothpaste, fine polishing compound and fine brush, and even oven cleaner with nitrile glove and fine brush to clean the interior beam pattern flutes. Oven cleaner left to set help. There may be a reflective strip adhered to the bottom of the lens that may have green algae. Some bleach. (Don't mix bleach and oven cleaner, if so!)
- Clean the reflector with simple green or dawn dish detergent.
- Rinse and inspect the lens. Should be clear with little or no yellowing. If cloudy, or pitted, a halogen light bulb may have exploded from being on, hot, and moisture contacting the bulb envelope. So, you may reject and hope for other yunkyard lenses, or buy new, or used replacements from eBay or someplace, though used may almost certainly require such a treatment to clean and glue back together.
- Let all parts dry thoroughly. A fan in a dry and warm area helps.
- If equipped, reattach the silver reflector strip at the lens bottom. I use Goop UV resist versions for everything. These are Marine and RV. WAL*MART has the RV version in a 5 or so oz tube in the camping-auto section hanging on a display for like 3$ (Though I'm sure better adhesive exist for such a task for the application)
- The lens has a protruding ridge that fits into a chamfered recess groove in the reflector body. Apply adhesive to both, secure together using tape or something. If using tape, cover lens with paper so tape adhesive does not stick to lens.
- Put lens-side down on paper. Use a fan to blow across the open light bulb socket to spur adhesive outgassing and curing. Goop makes a huge smell, for the amount you use, and it may take up to three-four days to cure enough to use, so leave in an area where the vapors don't bother other and pets. Also, verify your fan is in good shape to run for a few days. I had to take a few fans apart to lube the sintered metal bearings front and rear. Unless the fan had an oiling hole at both front and rear. I used Mobile 1 15W50.
- When done, inspect the work, Hopes the adhesive did not run into the lens fluted area. Else, reassemble and reinstall.
The big single dual bulbs on later 700 and the North American 900 run did not have an adhered reflector strip at the bottom fo the lens IIRC.
Those with the dual glass lenses used clips to secure the beastly head lamp assembly together, yet the same grey crusty (by now at 25 years) glue that can leak.
The round thing at the top of the head light assembly allows pressure to equalize without letting in liquid moisture and dust.
Else, if getting new, not all replacement headlight assemblies are made the same. Yet see the FCP Euro (closer to you) and iPd USA choices.
I'm unsure what 740 you have. Some models have merely two bigger square headlight assemblies. Yet there is a variation that uses fog lamps between the headlights and the center (bar and) grille. (ha!) There may be assembly variation.
Yet if you can see the reflector material is peeling, as you can see through the cloudy and yellow lens, you can get used and restore them or get new.
You may want to troll the yunkyards around NJ near you. Or try the Row52.com and check other nearby yunkyards with an online inventory.
The Row52 website has issues with Zip codes that lead with zed (zero) like yours.
Cop and paste this URL into a new browser window:
http://row52.com/Search/?Year=&V1=&V2=&V3=&V4=&V5=&V6=&V7=&V8=&V9=&V10=&V11=&V12=&V13=&V14=&V15=&V16=&V17=&LocationId=0&ZipCode=08741&Distance=200&HasImage=true&MakeId=243&ModelId=&Page=1&IsVin=false
Else:
http://www.swedishautoparts.com/740/Volvo-740-lights-&-lenses.html
FCP Euro 1992 Volvo 740 HEadlight Assemblies with Base (Not Turbo) Trim
(Big headlight, no fog lights)
https://www.fcpeuro.com/Volvo-parts/740/Headlight-Assembly?year=1992&e=914&m=20&page=1
Two sets of what FCP Euro defines as "economy". So, buyer beware. Note the part number for left and right headlight assemblies. Does not include bracket, turn signal, trim, and such. Just pull apart and put back together like legos. Watch the torque.
And when threading screws back in to plastic or composite material, don't cut new thread. Set the screw, and turn opposite to screwing in, and you'll feel a click or set. That is the lead edge of the screw finding the already cut thread in the boss or bore or screw hole. Cutting new thread in a hole with thread may mean you'll strip teh thread. Dunno torque values, yet to snug and then secure.
Has to be better for not so much $$$, those (borrowing Uncle Old Duke speak) shyster bastards!
All lighting from iPd USA for 700 series:
https://www.ipdusa.com/prodtype.asp?CAT_ID=970&numRecordPosition=0&categorycrumbs=
Not so good.
Search eBay (ePray?) for:
Volvo 740 headlights
Try Google and use the 'Google (is evil) Shopping feature.
You see LED inserts and such. Dunno if that helps.
Else, I'm sure others have had this issue with 700 with the same head light and can offer up some actually useful idea-rs for you.
Whetyher ePray or Google (is evil) shopping or what have you, you'll want to know the headlight assembly manufacturer before you buy, and ask around or search around for manufacturer name. See the reviews for what FCP Euro sells. One review says a dark spot. So, well, dunno.
You always have eCodes with glass lenses. From someplace.
From Tasca Volvo
The big headlights, no fogs lamps. Around 200$ smackers each.
Left
http://www.tascaparts.com/oe-volvo/1369604
Right
http://www.tascaparts.com/oe-volvo/1369603
With Fog Lamps in the front, like on Turbo 740 and fancy 760:
Left (Discontinued - NLA?)
http://www.tascaparts.com/oe-volvo/3534193
Right
http://www.tascaparts.com/oe-volvo/3534194
Hope that helps. yet some other brickboarder gotta have something for you.
Questions?
Happy Sundae!
St. Louis Style Supreme Pizza with Anchovies UH-Plenty
&
My Volvo 240s All Have Fleas!
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