Cracks on headlight housing

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Old Jun 3, 2015 | 05:02 PM
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Cracks on headlight housing

So cracks are appearing on my headlight housing on both sides. Noticed them a couple of months ago but it's getting longer on passenger side.
No impact damage or any other signs or marks of it.
I only drive to work and back and car hardly sees the major highways.
Dealership says its not a defect hence not warrantied and their sole reasoning is that they haven't seen anything like it before and assume it caused by impact/damage.
Needles to say, I'm not happy and don't want to spend almost 2k replacing both housings.

Has anyone else had this strange cracks originating from the bottom?






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Old Jun 3, 2015 | 06:29 PM
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Wow!!! Was the car exposed to extreme heat or cold a few months back? I know in Canada a last few winter were very nasty. The extreme low temperatures don't help our cars at all. On the first two pictures, do I see condensation inside the housings because of the cracks? The light housings on Tl should be able to handle extreme colds and heats.

Last edited by Jerry"O"; Jun 3, 2015 at 06:43 PM.
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Old Jun 3, 2015 | 10:12 PM
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If there is crack in housing, there will be condensation.
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Old Jun 4, 2015 | 06:07 AM
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Yeah it condensates now. First saw the cracks sometime in April and they were just starting. Now the passenger side is getting longer.
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Old Jun 4, 2015 | 06:27 AM
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It's interesting/bizarre that the cracks seem to be perpendicular to the bottom edge of the lens. And the fact that it is both lenses. What year is your car - any possibility of a warranty claim?
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Old Jun 4, 2015 | 01:24 PM
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They won't warranty it cause they haven't seen something like it before so it can't possibly be a defect!
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Old Jun 4, 2015 | 02:25 PM
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Somebody has to be first!!!
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Old Jun 4, 2015 | 02:28 PM
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2 grand? why? they don't cost that much lol
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Old Jun 4, 2015 | 02:47 PM
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I swear I've seen a similar thread on AZ before. Maybe you aren't the first! I'll try to find it but maybe someone else can search too.

EDIT - well that didn't take long, click here. It looks like that individual only had one crack but it's similar to yours and his were replaced under warranty. Someone else posted in that thread as well (posts 24-25) and they have multiple cracks that look like yours OP.

Last edited by ucf_bronco; Jun 4, 2015 at 02:52 PM.
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Old Jun 4, 2015 | 03:27 PM
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Originally Posted by Oh Sickest TL
2 grand? why? they don't cost that much lol

About $850 per housing here in Canada...then installation. $2,000 is probably just a touch "light".
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Old Jun 4, 2015 | 05:55 PM
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Originally Posted by ucf_bronco
I swear I've seen a similar thread on AZ before. Maybe you aren't the first! I'll try to find it but maybe someone else can search too.

EDIT - well that didn't take long, click here. It looks like that individual only had one crack but it's similar to yours and his were replaced under warranty. Someone else posted in that thread as well (posts 24-25) and they have multiple cracks that look like yours OP.
Thanks for the link to the other thread. Definitely helpful to prove that it has happened before and was warrantied.
Hopefully I can get it resolved asap before I burn out any bulbs.
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Old Jun 4, 2015 | 05:59 PM
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^^^^ Wow - $532.68 @ www.bernardiparts.com.

33101-TK4-A01
33151-TK4-A01

I realize this is US pricing but is there really that much difference -
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Old Jun 4, 2015 | 10:26 PM
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Seems like this a Canadian thing

The temperatures must be volatile up there
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Old Jun 5, 2015 | 07:38 AM
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Originally Posted by NBP04TL4ME
^^^^ Wow - $532.68 @ OEM Honda Parts & Honda Accessories - Bernardi Parts.

33101-TK4-A01
33151-TK4-A01

I realize this is US pricing but is there really that much difference -
Most dealerships have a 30% markup anyway.
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Old Jun 5, 2015 | 07:38 AM
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Originally Posted by Drei
Seems like this a Canadian thing

The temperatures must be volatile up there
Seems so. Looks like it's trying to separate from the epoxy that is holding it together.
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Old Jun 5, 2015 | 08:40 AM
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Originally Posted by LNJ
Most dealerships have a 30% markup anyway.
Not sure I follow. Are you saying Canadian dealerships are 30% above US?
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Old Jun 5, 2015 | 08:55 AM
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Originally Posted by NBP04TL4ME
Not sure I follow. Are you saying Canadian dealerships are 30% above US?
Normally there is a 30% markup on the cost price of any part. That's how they make profit.
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Old Jun 5, 2015 | 09:04 AM
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I understand that, but was originally trying to figure out why sockpuppet quoted $850 and I found local on line dealer $320 less. I'm not doubting or debating dealers mark parts up to make $$. I'm just surprised @ the $850 compared to the $532 where at this lower price they are still theoretically making $$. So its either gouging in Canada or FX, both or something else.
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Old Jun 5, 2015 | 09:04 AM
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You have to also consider the USD / CAD difference too (assuming the prices mentioned above are CAD).

1 CAD = 0.8 USD
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Old Jun 5, 2015 | 09:10 AM
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Originally Posted by ucf_bronco
You have to also consider the USD / CAD difference too (assuming the prices mentioned above are CAD).

1 CAD = 0.8 USD
Understood - that's what I meant by "FX" (foreign exchange)
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Old Jun 5, 2015 | 09:43 AM
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I work with FX daily so I'm all to familiar with that term. I didn't even see your post...both were done at 10:04 so we were on the same page at the same time, haha!
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Old Jun 5, 2015 | 09:57 AM
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Gotcha -
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Old Jun 5, 2015 | 11:03 AM
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Originally Posted by NBP04TL4ME
I understand that, but was originally trying to figure out why sockpuppet quoted $850 and I found local on line dealer $320 less. I'm not doubting or debating dealers mark parts up to make $$. I'm just surprised @ the $850 compared to the $532 where at this lower price they are still theoretically making $$. So its either gouging in Canada or FX, both or something else.
Even when we were at parity, the prices of new cars didn't drop to reflect the prices in the States. They waited almost 3 years to drop it a tiny bit.
At one point, the manufacturers were pretty much advising the American dealers to stop selling new cars to Canadians.
The local Mitsubishi dealership even told me that they will not honour the warranty on an EVO if I were to buy it in the States.
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Old Jun 5, 2015 | 11:10 AM
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Sorry -
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Old Jun 6, 2015 | 08:10 AM
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I have experienced the vertical stress cracks on both of my headlight housings. Unfortunately, I was past the warranty period. So, rather than pony up the ridiculous amount of money for two new housings, I purchased two damaged OEM housings on eBay, took the lenses off and swapped them onto my housings. I also used it as an opportunity to upgrade the projectors with TSX-R lenses. Still worked out much cheaper than new housings and the quality/appearance of the optics improved. FWIW, I'm also in Ontario.
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Old Jun 6, 2015 | 07:34 PM
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Originally Posted by RSXTINCT
I have experienced the vertical stress cracks on both of my headlight housings. Unfortunately, I was past the warranty period. So, rather than pony up the ridiculous amount of money for two new housings, I purchased two damaged OEM housings on eBay, took the lenses off and swapped them onto my housings. I also used it as an opportunity to upgrade the projectors with TSX-R lenses. Still worked out much cheaper than new housings and the quality/appearance of the optics improved. FWIW, I'm also in Ontario.
Do you still happen to have pics ofof thethe cracks?
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Old Jun 22, 2015 | 04:32 PM
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Acura Canada and Will the Service Manager from Fairview Acura came trough and replaced both headlight housings today.
Car looks like new again!


Last edited by LNJ; Jun 22, 2015 at 04:34 PM.
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Old Jun 22, 2015 | 05:03 PM
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Congrats! -
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Old Jun 22, 2015 | 05:54 PM
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I had a great experience at Fairview Acura. Just an FYI, they are going to move to a new space soon. I got a sale brochure for a moving sale.
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Old Jun 25, 2015 | 05:35 PM
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For what it's worth if someone else ends up with this issue or just interested if it happens to others...

I live in Alberta and I have the same issue. I have 3 long cracks on the passenger side with condensation inside the headlight housing and a tiny crack on the driver side with no condensation inside. Exact same spot, never been in any sort of accident or impact. I wonder if it's a stress point in the headlight housing.

I called a dealership and they said the warranty on something like this is 4 years/80,000 km whichever is first. Unfortunately I was out of warranty on the latter.

Dealership quoted me (Rounded) $950 a head light + $360 in labour or around $2,300 to fix. Currently chatting with my mechanic trying to figure out an alternative to replacing both headlight casings or a non-OEM product that might suffice (I really only care that I don't short out my electrical system). The above $2,000 is actually pretty close, and the pun added is correct as well.
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Old Jun 25, 2015 | 06:39 PM
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Originally Posted by DoubleF
For what it's worth if someone else ends up with this issue or just interested if it happens to others...

I live in Alberta and I have the same issue. I have 3 long cracks on the passenger side with condensation inside the headlight housing and a tiny crack on the driver side with no condensation inside. Exact same spot, never been in any sort of accident or impact. I wonder if it's a stress point in the headlight housing.

I called a dealership and they said the warranty on something like this is 4 years/80,000 km whichever is first. Unfortunately I was out of warranty on the latter.

Dealership quoted me (Rounded) $950 a head light + $360 in labour or around $2,300 to fix. Currently chatting with my mechanic trying to figure out an alternative to replacing both headlight casings or a non-OEM product that might suffice (I really only care that I don't short out my electrical system). The above $2,000 is actually pretty close, and the pun added is correct as well.
Damn...didn't even mean the pun on purpose. I guess I really am clever.

DoubleF: shoot me a PM. I'm in Alberta as well, and need to swap a headlight. Did one last year.
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Old Jun 25, 2015 | 08:38 PM
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I was expecting maybe around $1000-$1300 in repairs at most and nearly dropped the phone when they quoted me $2300. Quote sheet actually says $1900 in parts for replacement. What's in this headlight?

I wish there was a way to just mend it instead of replacing it... Used part DIY might be the only way to fix it for reasonable I guess.
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Old Jun 26, 2015 | 06:30 PM
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It's a weak spot in the moulding that's for sure. I think our climate just accelerates the defect.
Apparently the whole bumper has to be removed in order to replace the headlights.
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Old Jun 29, 2015 | 10:29 AM
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Originally Posted by LNJ
It's a weak spot in the moulding that's for sure. I think our climate just accelerates the defect.
Apparently the whole bumper has to be removed in order to replace the headlights.
Well, labour is labour, so the cost of that being double I probably wouldn't have batted an eyelash. But the base cost of the part at $950 each was the reason I had a deer in the headlights look that's for sure. I presume this is because they cannot just replace the plastic piece, but have to replace the whole headlight unit, but even then... $950.

I agree, it must be climate that accelerates the defect. We must be the lucky ones, as it seems this defect doesn't seem to be common.
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Old Oct 4, 2015 | 09:14 PM
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At the risk of reviving an old thread, I have further proof that this is a result of design and construction, not abuse.

I replaced a headlight with an OEM last year; passenger side. Had a visible crack, and got condensation (a lot). Ordered the headlight from AcuraOEMParts.com for about $540, with another $60 for shipping. Likely saved only a few dollars over buying local, once the FX is factored. Stupidly, it was important for me to go OEM.

I've since developed a crack on the driver side. My mechanic is pushing me to go aftermarket, but I've had this notion that the OEM are better parts. That changed today. I was cleaning out the garage, and took a look at my old headlight that was changed out a year ago...trying to decide what to do with the thing. I compared the crack in the old headlight, to the newly cracked headlight, and it's pretty clear the cracks are close to identical, with no signs of impact. I've attached images taken with my phone.

Newly cracked







Previously replaced








Based on this, I've lost my aversion to the idea of aftermarket housings. They may indeed not be better that OEM, but I doubt they're worse. And for the price difference, I would expect the OEM to last. In my experience, they don't.

Last edited by sockpuppet; Oct 4, 2015 at 09:21 PM.
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Old Oct 5, 2015 | 11:56 AM
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I think Depo makes an aftermarket one. The only problem I foresee you having is that it does not look entirely the same compared to OEM.
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Old Oct 7, 2015 | 08:28 AM
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I got some cracks too, not sure if self-inflicted or heat/cold extremes. One way or another I have found replacement ranging from $269.20CDN (amazon) to $742.42CDN (local dealer). Not sure if the amazon ones are new or used, toss a coin!! So, I am thinking of the aftermarket...

PS. no chance of warranty work for me, I am waaaay beyond any limits LOL. But the truth of the matter is on the '09 they installed total crap material there.
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Old Oct 7, 2015 | 08:30 AM
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wow! they def. missed this in their QC process.
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Old Oct 7, 2015 | 03:32 PM
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I was successful with Acura customer relations for a portion of the replacement costs even though I'm beyond warranty (it was still an expensive repair bill though). Sockpuppet, you should give it a try. I think you have legs to stand on for arguing because you have the invoices and multiple cracked headlight assemblies.

For reference:

IF YOU SEE CRACKS AND CONDENSATION, REPAIR/DISMANTLE AND DRY IMMEDIATELY! The way this thing is designed, the condensation will leak down through the headlight and could destroy your ballast, light bulb and fuse which would put you out another sum of money (combined cost nearly as high as one of the OEM headlight assembly IIRC).

@Tony: I wouldn't be surprised if you didn't impact it. I wonder if there's a defect in a bunch of assemblies. My second guess is that somehow the headlight assembly is absorbing impacts from the body of the car. Light taps on the headlight assembly at temps below freezing probably could crack them. I wonder if putting some type of soft foam tape or something under the headlight assembly can reduce the chances of it cracking.
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Old Oct 8, 2015 | 10:52 AM
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Originally Posted by DoubleF
I was successful with Acura customer relations for a portion of the replacement costs even though I'm beyond warranty (it was still an expensive repair bill though). Sockpuppet, you should give it a try. I think you have legs to stand on for arguing because you have the invoices and multiple cracked headlight assemblies.

For reference:

IF YOU SEE CRACKS AND CONDENSATION, REPAIR/DISMANTLE AND DRY IMMEDIATELY! The way this thing is designed, the condensation will leak down through the headlight and could destroy your ballast, light bulb and fuse which would put you out another sum of money (combined cost nearly as high as one of the OEM headlight assembly IIRC).

@Tony: I wouldn't be surprised if you didn't impact it. I wonder if there's a defect in a bunch of assemblies. My second guess is that somehow the headlight assembly is absorbing impacts from the body of the car. Light taps on the headlight assembly at temps below freezing probably could crack them. I wonder if putting some type of soft foam tape or something under the headlight assembly can reduce the chances of it cracking.
I second this. That's exactly what happened with my first headlight. Don't believe anyone that tells you the ballast is sealed and separate, so water can't get in. Mine was full of water...I still have the (previously) waterlogged ballast to prove it.
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