I'm sick of my sucky suck suck big square headlamps. They suck. I know it's possible to hook in the stuff from an '80-'85, but I'm wondering how much I need to change? Obviously the housings for the lights, the surrounds, but then, would I be able to keep my corner lenses or grill? My issue is that I have very little money to spend on this, otherwise I'd go for the euro glass stuff. In terms of the wiring, I'm planning on hooking in some relays soon anyways, so that won't really be an issue....I'm pretty good with automotive light wiring by now. thanks for any input!
Nate Gundy
--
'86 240DL sedan, 260K miles, M46, K cam, 25/21mm sways, 260 front and wagon rear springs; http://valvespringcompressor.weblogs.us/

You can convert to 7" round sealed beams or H4s pretty easily. Go
to a Volvo _Truck_ dealer and ask for part # 8026546. This adapter
was used to fit (cheaper) round lights to Volvo tractor trailers
that came from the factory with rectangular lights almost identical
to those on the post-86 240 series. Daniel Stern, the lighting
guy, claims that it fits later 240s with no modifications.
.
-b.

wow, now that sounds like a lead....any clue how much those would cost? I hope we're not looking at 85 bucks a pop....but still, worth checking up on. thanks a lot!
Nate Gundy
--
'86 240DL sedan, 260K miles, M46, K cam, 25/21mm sways, 260 front and wagon rear springs; http://valvespringcompressor.weblogs.us/

You could just replace those old clouded yellow lenses with new stuff, or good lights from a parts car, and not worry about it.
FCP has these units now if you want to pull the front covers off:
HLPV081 Left Head Light Lens-Plastic $55.00 Aftermarket
HLPV082 Right Head Light Lens-Plastic $55.00 Aftermarket
Others sell new and used headlight globes cheaply.
I don't know why everyone has such problems with these things. I can see just fine with all of mine, as long as they have good lenses. And I drive some pretty dark roads at pretty dark times of day.
--
Rob Bareiss, New London CT ::: '87 244DL/M47- 225K, 88 744GLE- 209K, 91 244 183K. Also responsible for the care and feeding of: 88 745GLE, 229K, 88 244GL, 146K, 87 244DL, 235K, 88 245DL, 236K

Poor optics. I had a hard time adjusting my plastic headlights because of the scattered beam. The lenses were yellow and I'm sure the reflector wasn't in like-new condition by any means, but the light output was not good. I use e-codes now, and the difference was amazing, and I still use 55/60 bulbs. I wanted to use 80/100 bulbs in the e-codes because the metal/glass construction will safely allow it, but I just haven't seen the need to redo the wiring yet. I'm still impressed by ~20 year old e-code headlights, and I've had them on the car for about a year. The beam cutoff on the top is very sharp, and there's a very noticable hot spot that makes aiming them really easy.
--
| 740 Decor panel for sale on ebay |
| 740 Turbo grille for sale on ebay |

I wonder if the lighting, post-86, issue isn't compounded by inaccurate beam adjustment.

'75-'85 hood won't fit '86-'93 cowl panel. Options are to cut out cowl and replace, or butcher an old style hood so the dip at the back doesn't hit the cowl when you try to open it.

In other words, lots of work, and often not worth it. I like the e-codes better.
--
| 740 Decor panel for sale on ebay |
| 740 Turbo grille for sale on ebay |

If it were that simple, a lot of us would've done the swap already. But the fenders are different, the hood, the grill, valence panels, etc., so essentially, the entire front end needs to swap over. Though it's all bolt-on stuff, it does take time.

Me ... for my 245, I feel like I'll prolly end up fabricating some adapter plates to use some other make's headlight setup and getting some trim pieces made to fill in the space.

-- Kane
--
Blossom II - '91 745Ti/M46 ... Bubbles - '74 144GL/BW35 ... Buttercup - '86 245GL/AW70 ... The Wayback Machine - '64 P220/M40

"But the fenders are different, the hood, the grill, valence panels, etc., so essentially, the entire front end needs to swap over. Though it's all bolt-on stuff, it does take time.

Me ... for my 245, I feel like I'll prolly end up fabricating some adapter plates to use some other make's headlight setup and getting some trim pieces made to fill in the space."

Kane--

Before anyone tries to swap out the front clip from an early model to a late model, check out the fit of the hood at the cowl panel. I'm not sure the newer and older are the same--and if they're not, it would be a killer job to cut out and weld in the proper cowl, which would then affect the vent and internal drains and so on...


I've been spying out other makes myself, looking for one that's a likely fit. I think an older Grand Cherokee looks close, but I haven't got one up close with a tape measure to find out. There's also a Ford van that might work.

For it to look clean, as well as overall dims, you have to have a similar centerline-towards-fender curvature AND the right vertical slope. But with so many other cars/years out there, all with unique headlights, I suspect something will come along.

Anyone who finds a good fit, please post it. This is a little detective work anyone on the board can do that would help every Volvo owner.

Doug Harvey

I was figuring on using 7" rounds + foglights - I can always get a piece of "scratchproof" lexan cut to fit afterwards for a flush fit.

It was previously mentioned that Rodeway uses some on their semi's, but I was hoping for something a bit more cost effective (like using junkyard parts + a little fab time). If nothing else, for a good challenge. :)

-- Kane
--
Blossom II - '91 745Ti/M46 ... Bubbles - '74 144GL/BW35 ... Buttercup - '86 245GL/AW70 ... The Wayback Machine - '64 P220/M40

I too am very interested in a conversion. I will try to swap them out this weekend. I just picked up an '86 and will try the '83 lights. There are still slots in the top radiator support for the plastic retainer clips. Funny they didnt change that stamping die.We have the H4's in the '83 and they provide good light and look better too. I like the idea of the Volvo truck units. 7" rounds would have an interesting look to them.

So the assemblys from the 4 square beam pattern simply are too wide and/or tall to fit into the current places? I don't really care if it looks less than wonderful...if I had to cut pieces off and whatnot....as long as I could get the lights mounted securely. I don't quite see why it could require changing the entire front clip...but then I've never tried. I just think there's got to be a relatively easy way to mount either a 7" round or 2 rectangular beams in there. I guess I'll just have to start looking for cheap junkyard possibilities to play with...
Nate Gundy
--
'86 240DL sedan, 260K miles, M46, K cam, 25/21mm sways, 260 front and wagon rear springs; http://valvespringcompressor.weblogs.us/

I don't quite see why it could require changing the entire front clip...

Here's what I know, and I have a 1986 and a 1984 side by side.

The cowl grille intake is diffrent - old is depressed and across the middle, new is not depressed, and there are two - each near the side and blow the wiper.

Corner lights on the new are shorter and are attached to the backer piece that holds the headlights. Old ones attach to the fender IIRC.

Hood fit to the top line of the headlights is different. Old has a center part that sticks out a bit and covers the top of the grille. New is a single line across, and the grille slopes a little backward.

Now - yes those large plastic square lights are miserable. On my 1986 the RH is yellow, the LH is clear and has a 1/2 inch of water making waves inside (we don't get freezes much). Best solution I have found is to get either a lens or a whole light from eBay (or somewhere) and re-hab, re-seal, de-yellow the "new" one and then swap it in.

Consider adding driving lights, too.

Good Luck,

Bob

:>)

How do you "de-yellow" the headlights?

You could try polishing the outsides of the lenses with toothpaste
or a similar mildly abrasive substance. This method helped partially
"de-yellow" my car's HLs.
.
-b.