I know I posted how I fixed mine. Where it is, I don't know.

 

I am also in this boat. I looked for your post Tortelious but didnt see it. will search again later.

 

Here ya go :

headlight adjustment

looked through manual ans online cant seem to find answer. i know the location of the horizontal and vertical adjustment screws but which one is for vertical adjustment... facing the front leftbside pass and right driver.. is the vertical adjustment the screw closest to center of car or one...

www.passatworld.com

How to fix vertical headlight adjustment w/ pictures

Like many of you, my headlight adjustment ball and socket disengaged. I read the posts here about this issue and thought I would try to fix the problem. Although my headlights were aftermarket, I did notice that the adjustment screws are marked as to up/down and right/left. Also, while turning...

www.passatworld.com

good luck.

 

Thanks!

 

Thanks, but that doesn't answer the question... With the gears broken, how do I (you ?) adjust the headlights?

 

The metal post that the 2nd plastic gear is on is attached to the adjuster inside. You can turn that with pliers, but it's tedious.

 

Thanks, PZ !
(I was hoping for an easier way, but if that works, I'll go for it )
Steve

 

NOTE: this is not a direct answer to an adjustment method for a headlamp assembly with a broken adjuster.

RA has the OEM Hella headlamp assemblies for ~$107 each (non-Xenon, with bulbs, too, if I recall correctly). If your lenses are getting cloudy, too, this is a worthwhile refresh for your night lighting. I have a discount code that is valid until near the end of January, too - use 124874195112628828 .

I replaced mine with these a couple of years back and am glad that I sprung for the parts rather than trying to refresh the old lenses/assemblies.

 

I did what khnitz did a couple years ago and I'm glad I did. I didn't have any issues with the aim, but they were cloudy, the mounts were busted and the wiring was going to hell inside the housings. I had already refinished the lenses once and I knew I didn't want to do it again because of the mess.

Definitely worth the money. The headlights are the exact same that came on the car, with the exception of the missing VW/Audi logo. I think the originals on my 01.5 were made in Germany and the new Hellas were made in Slovakia (I think).

 

khnitz and pete029, thanks for the lead on replacements from RA - do you have a website address for them? Thanks!
(lots of RA, R&A, RAuto, etc all over a google search)

Steve

 

I didn't want to step on any sponsors toes, but I'm referring to RockAuto.

 

RA = Rock Auto Understood;thanks

 

You can reference any business you want as long as they are legal.

 

Correct. When I recommend a vendor, it may not necessarily be a site sponsor. It's from my personal dealings with them on my own parts.

Rockauto, FCP Euro, NGP Racing (because local to me), and even Amazon/Ebay for non critical small parts are my go to places.