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How to replace a cracked headlight lens 940 900

posted by  trinck44 on  Thu Feb 26 10:42 CST 2004
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Can someone please give me some insight into how I replace a cracked lens on my 940 headlight? I see lenses and complete headlights available.
I was told from one dealer that I need to cut the old lens off with a razor blade. Does that sound right?? I guess I reseal the new one once it's on??
Do I need to pull the entire headlight out and if so...How?

Just wondering if I should try to replace just the lens or replace the entire headlight which is about twice the price of the lens.

Thanks

Tom








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    How to replace a cracked headlight lens 940 900

    posted by  Brian S on  Thu Feb 26 11:25 CST 2004
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    It is possible to purchase just the lens. I got one from volvolamps.com last fall... I think FCP Groton may carry them, as well. Cost is probably about $90, as opposed to maybe $160 for a new capsule. The lens I got is an aftermarket piece, made of heavy plastic, and seems to be good quality. The original lens is glass (at least on my '93 with fogs next to the headlamps).

    To replace the lens, you need to remove the headlamp capsule, cut off the old lens, and glue on the new one... I used clear RTV for this. There are instructions in the FAQ that will help you get the capsule out. It's a pretty easy & straight forward job... toughest part for me was removing all the broken glass bits & old sealant, once the unit was off the car.

    Another option is to replace the whole capsule with a used one from a salvage yard...

    - Brian '93 945T







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    How to replace a cracked headlight lens 940 900

    posted by  Steve on  Thu Feb 26 11:03 CST 2004
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    last visit: Fri Oct 24 07:16 CST 2014
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    Usually, you need to replace the entire capsule. If the dealer has just the lens, then cut the old one off and glue the new one with clear silicone adhesive.








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    How to replace a cracked headlight lens 940 900

    posted by  Kane on  Thu Feb 26 11:03 CST 2004
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    That's pretty much the gist of it. It will be easier to do with the unit out, though. Remove the corner light unit (single tab clip from inside) and the grill. IIRC, there's a total of 6 bolts to be removed, using a mix of 10mm and 8mm sockets and wrenches.

    Chances are, the glue on the original lens is already loose. Clear RTV silicone (in a tube) works to sealing - others may have better suggestions.

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







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