My 1979 244GL has the large rectangular headlights that are vertically aligned by a screw with a ball end that is retained by being inserted into a rubber-lined socket that is pop riveted to the car chassis. The screw goes through a threaded nylon flange that is pop riveted to the headlight.

Over time the ball end of the screw gets "fused" to the rubber-lined socket and forcibly extracting the screw destroys the aged hardened rubber lining. Also forcing the ball back into the socket fractures the threaded nylon flange on the headlight.

The FAQ suggests the following: "Single Unit (No Fogs) These screw adjusters come in an assembly. The up-down axis is adjusted by Volvo p/n 3534201-3. They cost about $20 each. Carefully prise off the headlamp capsule from the broken adjuster screw and replace from the front". But in Australia with monopoly + ransom pricing these "slow-moving-spare-parts" will be A$60+ each - A$120+ for a pair!

My two possible (practical?) approaches are below but I'm sure that BrickBoarders have some better neat & low-cost ideas to get around this problem:
1. replace threaded nylon flange with threaded aluminium flange using flat strip of alum. Tap the alum or use locknuts. Secure the ball-screw in its socket with RTV after alignment. Grease ball prior to insertion into RTV so it can be easily? removed?
2. use threaded alum flange as above. Cut off ball-socket & replace ball-screw with plain screw and use a pair of lock nuts on each side of chassis to retain screw. This would require removal of the panel above the headlights (containing the hood-release lock) to adjust the alignment - bit of a hassle but only a few minutes extra work.