On a 2009 (basic HID lights - no washers/afs) - the internal adjusting mechanism is broken in both (came that way). I need to either:

a) open and repair the mechanism (if possible)
b) replace headlights w/take-off or aftermarket.

This spring when the weather is nice, I’ll take off the bumper and repair/paint it (lots of rock chips). At that time I’ll have to repair the lights, if it’s possible, or find replacements.

Has anyone ever repaired the adjusting mechanism in these?
Any affordable aftermarket options? Not interested in dropping $1k, though.

 

I don't think any adhesive will work long term heat cycling plus vibration will cause a failure sooner or later. If you do go aftermarket make sure they are CAPA certified this means they are approved by insurance companies are match the originals as far as light output. I've had mixed results with aftermarket from Depo, TYC and others.

Not sure I'll ever buy aftermarket again for headlights, other lights yes.

 

One of my GS headlights was opened for some repair (I got it like that from the last owner). It's still going strong. Also, on another car I own I had payed someone to repair it using pvc welding. No issues for more than 5 years, so I would say if you find someone who knows their stuff in opening and reseal it, go for it.

Or buy some used headlights if you want to go cheaper. They are still OEM and you'll not need to spend a fortune. Maybe give them a polish and some protection afterwards.

 

I have had no problem opening and resealing headlights in the past with silicone or butyl tape; I’m not too worried about that. I too would prefer OE lights so repair is my 1st choice. Not sure if McGyvering those adjusters will work as I can’t really see the assembly until I open them.

I am ok w/the opening/resealing. Repair is a question. With new OE headlights being $600/ea, a used pair are $500 I’ve found. Really high.