I was washing my car yesterday and noticed a 1/4" hole in the passenger side lens and a 1"-2" bullseye inside the assembly. Do any of you know if I can repair this or do I have to buy a new headlight? How much should a new lens or repair job cost?

 

You can buy replacement headlamp assemblies at Ebay, local junkyard, or some online part stores. They are around $90-110 per side for the OEM ones.

 

I got a 1/8" hole in one of my headlights a few months ago. I sealed it with epoxy, but it ran down on the inside and it turned yellow. If it wouldn't have run, I would be o.k. with the repair.

A while back, one of the guys here was able to separate the glass lens from the lamp holder by putting the assembly in the oven at 200 degrees for 20-30 minutes. Obviously, you remove the clips first. The heat softens the glue so that you can pry them apart. YOu could then put some epoxy on from the inside with tape on the outside to plug the hole. It would be a good opportunity to clean out the broken glass.

To put it back together, heat it again.

Pep Boys sells a winshield/headlight repair kit. The instructions say to repair a headlight, cut a piece of the clear plastic container the kit came in, and glue it to the headlight with the resin included. The resin is supposed to harden with UV light, but mine never did. Evidently this stuff has a finite shelf life.

BTW, the headlights on Ebay are repos, not Nissan OEM. I bought one and it is very good quality. IIRC, I paid $75 for the repro. I bought a headlight from Courtesy 2 years ago for ~$150. YMMV

 

Here is a place you can get a new headlight from. Not sure if they are OEM though.
http://autopartsplanet.bizland.com/a...lanet/id7.html

 

Thanks guys! I think I'm going to buy the repro for $63. I never had to much luck with those repair kits. Thanks for all the info.