My 1996 1.9TDI has just failed its annual Government safety test (called MOT in UK) because the headlight adjusters have reached their travel limits so the beams are incapable of further adjustment. No explanation was offered on how this could happen. The only reasons I can think of are:
a) The mechanical adjusters have worn out - although this is hard to believe, given that they are rarely used.
b) The internal optics are coming apart.
c) The cars suspension has worn significantly to affect the levelling.
d) Could be bulb problem.

The internal (facia) electrical adjuster seems to work OK.

Apparently, the solution is a pair of new headlights costing the equivalent of $459 each, to include labour.

Has anyone else experienced this problem?

 

you can buy just the adjusters i think check with the dealer they will be able to tell you