How to remove headlight glass? - 93 850 tall headlight

Post by **scot850** » 04 Apr 2025, 17:23

When I was at the junkyard last weekend I pulled a lonely headlight from a low mileage 93 850 GLT sedan.

Only reason was it was an actual Volvo headlight on a car with less than 90k miles. It has a few chips in the glass which is normal here. However, I want to remove the lens as the headlight rear had been left open after someone had taken the headlight bulb and snow got in so it is damp inside and a little dirty.

Been a long time since I worked on a headlight this old on a P80, and I don't recall the plastic tab on the upper and lower sides covering 2 of the class clips. Does anyone recall ever removing these plastic covers and if so how??

: 93 850 Tall headlight

This is the plastic covering one of the glass clips. There is a 2nd one on the lower side of the headlight also:

: Plastic tab covering glass clip

Any guidance appreciated!

Neil.

Post by **Krons** » 04 Apr 2025, 21:13

A little different but the early P2s used glass and I swapped a lens on my kids 2002.
viewtopic.php?p=627144&hilit=Headlight#p627144

If I recall right it was simply removing the metal clips and give it a tug. In my case the silicone type adhesive was pretty crusty and did not put up a fight. Possible to pull the bottom first and then rotate up where that plastic ‘clip’ overhang is?

Post by **scot850** » 04 Apr 2025, 23:03

The 2 plastic covers feel like they are either really stuck or are glued in place. I tried gently prying them in all directions. I though maybe they were sliding lock clips and slid sideways to release them. They started to make plastic cracking noises even after spraying with silicon oil.

The metal clips are just the standard P80 spring clips and those I have done many, many times. For this unit I can remove all but 2 under the plastic covers. I was hoping someone will possibly give me the 'A-Ha' moment.

I have a handle on the P2 units, but those I will avoid unless I really have to!

Appreciate you taking the time to respond Krons!

Neil.

Vova585 · Post by **Vova585** » 05 Apr 2025, 21:42

Never dealt with such design. Previously when I was contemplating resealing glass on my car I came across suggestion to "bake" headlight in oven at 250f for 10-20 min depending on sealant and it should make glass easily detachable. Or maybe try gentle "heat gun" approach around those clips and hopefully they will slide(based on pic it seems like logical design). Windshield selfleveling silicone was also suggested for resealing. Another alternative to reach to IPD and ask if they have any knowledge on this(if they sell glass kit they should have toos to remove old)Sorry can't be of more help.

Post by **scot850** » 05 Apr 2025, 23:01

These older units have glass lens covers. They are easily removed after removing 7 'C' shaped clips that lock the glass portion to the plastic housing holding the clips. Most are easily done. In this case, there are 2 of the clips hidden under the plastic 'caps'. One on the top and the other diagonally opposite on the bottom. I may try heat to help see if it will help me to move or remove the plastic caps. Strange design that I don't recall seeing on a 93 850 GLT we used to own. Certainly, the 95-97 headlights on 850's are more like I am used to.

Appreciate the suggestions,

Neil.