Hello All! I have a 2004 S80 T6 with factory HID headlights. One of them got a lot of moisture in it and the bulb burnt out. The dealer wants to replace the entire headlight assembly which is ~$1000, so that's out of the question. I therefore removed the assembly myself to see what the problem was and lo and behold, the gasket behind the lens is shot (the lense itself is fine). Volvo doesn't sell a replacement seal or gasket. I cannot seem to find anyone that sells just the gasket for the HID headlight assembly. Can anyone offer any suggestions on obtaining a replacement gasket, can I make one, or will I have to buy a new lense w/ gasket? Thank you!

 

You might be able to make one, check your local auto parts store.

permatex.com/products/Automotive/automotive_gasketing.htm

 

To those who may be interested, I made my own gasket/seal out of clear Silicone II sealant, which thus far appears to be working well. Just pull the clips off the headlight, remove the lense, discard the old gasket, and fill in the gasket's groove with the sealant. Far better than $1100 for a new HID headlight assembly.