Our 83 240 wagon got punched in the front (slid on ice). Most metal, hood fendersetc are good but the grille and headlight frames got busted. Can we swithc from early 4 square lights to the newer big square lights without changeing any sheet metal other then the "buckets" and trim ? If so any body got a good deal on used ones ?
Thank you
83 240, 84 240, 93 850

Those other guys are right on the money.

For everything you ever wanted to know (and maybe more) about 240 headlights, see the FAQ at:

http://brickparts.d--r.com/headlightFAQ.htm

You should keep the old headlights and just get the frames and grille from an '81-'85 240. The '86-'93 240 that used the large plastic headlights also have different fenders, hood, grille, turn signals, and radiator support. Those plastic headlights also don't give the quality of light that you can get from the 4 rectangular headlights.

You could replace your headlights with e-code glass lights that are similar in size to the '86-'93 headlights, but these are very rare, and when you do find them, they are expensive. They are a direct swap for the 4 rect. lights, so you wouldn't need to swap a bunch of parts.

See my links page under used parts for some good sources if you need the headlight bezels and/or grille for your car.
--
Michael -- 1987 244 GT | Volvo 240

I do not think that is a good idea. The fenders are different and require the correct ts housings. The headlight parts may not fit either, but besides that, the quad lights are plentiful, cheap, and with H4/H1 sets, great for illumination. The big plastic lenses are hard to find in decent condition, expensive and not that great for light. You can find H4 Euro versions of the big lights but there is major money involved and again, they may not (probably won't) easily install in the older car.