Headlamp Self Levelling Issue

[orangeeric]

One of my headlights was low, so I visited the local charlatans. They were more than happy to help (of course...).
The bill - £587 + VAT for parts plus two hours labour (£240 +VAT) - oh and a three week lead time.

So what were they fixing? Well, the leveling mechanism is managed by two white cogs (about 15mm dia) sitting on each side of each lamp unit. One of them had broken (apparently a known fault) as the plastic perishes over time because of heat from the engine.

It would appear as usual, that Audi's solution to a 20p problem is to swap the entire unit out - there are no sub parts available. I suppose I should be grateful they didn't suggest swapping the Bi-X ballast and bulbs too.....

Has anyone else experienced this and if so, did they find a more satisfactory solution? If not, any bright ideas?

I've looked for a donor unit, but the usual world of part numbers etc. has made it impossible to source one (how many different part numbers for an A6 headlight??!!)

[Shoppinit]

I have noticed that if I hit a big bump, then it will knock the headlights out of alignment. I have had this on Golfs, too, which use the same system.

It's a pain because you need to use the vagcom to set the level (not to mention the aiming machine of course I don't have).

I don't think you can buy the individual compenents, but I would have bought a 2nd hand headlight and canibalised it.

[bakustax]

I had this issue and looked like failing the MOT on it.
The Mechanic at the local garage managed to attach a small bit of plastic stick where the cog had snapped with a bit of silicon and was able to ajust......a bit Heath Robinson but save me the cost of a new Headlight....think the quote was £540 plus VAT