I have a '01 S60 with a cracked headlight lens (plus the other side is filled with condensation).

I see where a number of the online Volvo parts specialists sell the lens in the $70-90 range so I know I can get a replacement without buying the whole headlamp assembly.

I took a look at mine and from what I see, I need to remove the front bumper????

When you open the hood, there is one stainless clip exposed and about 3 black plastic lock tabs. But those are just on top. It looks like there is more to it then that but it looks as though the bumper is in the way.
I tried searching for any existing threads on this but couldn't find any. Anyone here do this? What are the basics?

And as to the parts available online, are they all the same and go with my preferred online vendor or are there differences I should be aware of?

 

We had our 2004 S60 headlight lense replaced this month at our independent Volvo repair shop. Due to winter weather conditions and the need to get it fixed ASAP, we didn't try replacing it ourselves. Volvo Dealers Parts Shops only sell the entire headlight assembly ($500 plus) because they have found the seal around the headlight doesn't always hold and air and dirt get into the reflector and inside glass and degrade the headlight strength. However, my daughter is on a tight budget so we went the glass replacement route. The repair shop charged $335 ($200 for the lense kit and $135 for labor) and completed it in one day.......not bad since we needed the car repaired ASAP. Part of the front bumped cover does need to be removed. My daughter found a DIY process posted on the Internet........do a Google search and you should be able to find it with photos.

 

http://www.ehow.com/video_5359903_re...t-volvo-s.html

 

Old thread, but I have cracked lens on both sides. I think someone took a hammer to them when I was down town LA late.


Anyway, I purchased URO glass replacement lens. The local O'Reilly auto parts had the 3M 8610 (1/4) butyl rubber.
Yes, the many youtube videos indicate reusing the old sealant is okay, but since I need to pull the bumper cover, I do not want to do this again.