I need to replace the headlight lens on my '94 960 (driver's side). The dealer tells me it's only available as a full assembly for $216. I've checked all of the recyclers around and nobody has one. Any idea where I might be able to find one cheaper?

Thanks,
Mike

I have some spares lense or lense assy I drive a 92 960 but have a 93 960 for parts that way can keep it on the road Steve email stevetheweave1@juno.com

I got a replacement lens of the type you need for about $90 from newandusedvolvoparts.com. The lens is an aftermarket piece, and plastic, rather than glass... pretty good quality, though. Removing and reinstalling is pretty easy... good instructions in the FAQ... toughest part for me was pulling all the broken bits of glass off the reflector.

- Brian '93 945T

Try Lakeview Auto Charlotte, NC 704 393-8655
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Leon Ramseur in NC, 1997 855, 1995 945, 1990 760, 1990 740 & 1990 745. 90 740 & 97 855 FOR SALE.

I thought that FCP Groton sold a plastic equivalent for about $50 each, but I don't see it on their website now. I have seen this item "in the flesh", but I don't know the manufacturer. You might call FCP Groton and ask them about it. To utilize this method of repair, you have to remove the headlight; remove the small metal clips around it; pry apart the glass lens from the plastic reflector & reassemble with silicone seal using the plastic lens.

FWIW, FCP Groton sells the headlight "Lens/Reflector Assy" for $158 each. This is the genuine Volvo part with the glass lens. It doesn't include the foglight. This is about 30% less than your quoted price.

Having worked in a plant that made automotive headlamp assemblies I can tell you that the aluminized reflector degrades significantly in the presence of moisture. If you have a broken glass, even if you manage to unglue the lens from the reflector by cutting through the rtv, you will most likely have a reflector that aint what it used to be. If you can get the whole assembly for 158 and it is a glass lens, go for it. If you are in a state that checks headlamp output on inspections, it might fail on that side just cause of the reflector.
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97 S90 with 162K miles still going strong

When I replaced the headlight assembly on my 92 960, it was not an easy task to say the least. I could not determine a way to remove the headlight without first removing the foglight. If there is, I missed it. Otherwise it's a pain in the butt.
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John Shatzer, '97 V90 @ 105K

For my 95 960, I got a replacement from Erie Vovo. 888-865-8613
www.erievovo.com yes, leave the "L" out of Volvo.
Good people to deal with. Replacing it was a pain. If you have a headlight wiper, youhave to remove it before the headlight will come out. Two screws underneath, right angle torx helps