About 4 years ago a deer jumped out of the woods and slammed into my right front .... As a result, I had my mechanic swap out the light assembly for a new one. I've always liked this mechanic in the past, but now, 4 years later, the reflector is totally pocked with rust and I'm in for another assembly. I can hardly see at night with anything less than brights. Anyone else having trouble with poorly manufactured lights on this car? I'm very frustrated. Mechanic and dealer wanted about $500 per to replace both w/ new (I'm swapping both out, the other is dim, but not so bad). I've found salvaged for $75 and am going to have another indie do the install.
Others having this experience?
Any advice? I think I recall some condensation in that light early on.
Also just had this mechanic redo front brakes (calipers, pads, etc.) for $1200. This turned out to be what the dealer would have charged. I've loved these guys, but now I feel like I might be getting ripped off.
Reality check?

 

ditch the OEM lenses and buy some E-code glass from FCP groton (think it should be just over $100 for both sides). they have a MUCH improved light throw pattern when compared to the OEM DOT spec stuff. put in some good low-beam headlight bulbs (sylvania silverstars are good but burn out frequently, PIAA has some good stuff too) and call it a day. all of this can be done yourself. If you need a new housing, get something cheap on eBay or craigslist that has bad glass (because you're going to replace anyway)

here's some good reading on the subject:

Swedespeed Forums - E-Code Lens

Swedespeed Forums - E-Code Lens or Projectors?

Swedespeed Forums - e-code lenses or complete assembly?

 

Don't know about your lights - my '98 S70's are original and crytal clear. My S80 had some condensation once - discovered that I had not properly screwed th back on when changing the bulb. I also have an Infiniti and an Acura and both have lights that seem (to me) more poorly constructed than either of my Volvo's. Maybe you got an old salvage LAST time. You never know what you get out of a salvage yard.
$1200 for all that work on the brakes is about right from a dealer - my mechanic charges the same rates as well. He also only uses Genuine Volvo parts ( new, new used or 'rebuilt') and is certified on all Volvos. So, I don't mind paying to get it done right. He has erred once, but made it good and then replace a cam seal for free as an 'apology'. To me, this sort of service is worth the extra few bucks I would save by going to "Bob, the shadetree mechanic - we service all brands".
I sometimes twist the wrenches myself to save a few however.

 

Most are not now
The reflectors come apart internally and as you noticed rust
I have a perfect, very low mileage left headlight (1998-2000) and maybe a right (I'll have to look) if you need one.
In as new condition
jrl1194(at)aol(dot)com
Jim

 

///\\\ PM sent.

Thanks for these responses. NOT up for a rebuild on my own, though I can see the logic. RIght now I'm waiting on delivery of the 2 salvaged assemblies. Good guy, who said they were in perfect condition. I'll quiet down about my mechanic thanks to the above. Generally, I feel very confident. I've just been blown about with some big expenses lately, so these were unwelcome bills!

Important question Can I sub in a more high intensity bulb? If so, what?
Looking at these 2: http://www.amazon.com/Sylvania-H7-BP...1998&carId=001
or
http://store.candlepower.com/osraulhiouh7.html
based on other posters on the forum.
cheers

 

super easy! you can do it! it's ok though.

and those sylvania bulbs are definitely going to make a difference.