240 Headlamps

rustytoba · Jun 14th, 2015, 13:21

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 · Jun 14th, 2015, 13:29

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 · Jun 14th, 2015, 17:06

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 · Jun 15th, 2015, 08:09

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 · Jun 15th, 2015, 13:46

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

Rusty

Bugjam1999 · Jun 16th, 2015, 23:06

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.

Jun 14th, 2015, 13:21	#1
rustytoba Master Member Last Online: Nov 24th, 2023 01:11 Join Date: Dec 2009 Location: Glasgow	240 Headlamps 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

Jun 14th, 2015, 13:29	#2
Velorum VOC Member Last Online: Apr 17th, 2023 20:49 Join Date: Dec 2004 Location: Newquay	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! __________________ Past Volvos 340's (2), 240 saloons (4), 240 estates (5), 740 estate (1), 760 saloon (1), 940 saloon (1), 940 estate (1)

Jun 14th, 2015, 17:06	#3
Beetledrive Member Last Online: May 5th, 2019 21:07 Join Date: Mar 2011 Location: Norwich	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. Last edited by Beetledrive; Jun 14th, 2015 at 17:08.

Jun 16th, 2015, 23:06	#6
Bugjam1999 Master Member Last Online: Yesterday 15:27 Join Date: Nov 2012 Location: London and Cambridge	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. Last edited by Bugjam1999; Jun 16th, 2015 at 23:09. Reason: Damn you autocorrect

Jun 15th, 2015, 08:09	#4
Clifford Pope Not an expert but ... Last Online: Today 08:06 Join Date: Dec 2001 Location: Boncath	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.

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