I believe size and mounting never changed in gen one but after the first few years the optics in the lenses were changed to try and improve light pattern. This was also done on the “cloud cars” because the headlights were so small, actual road lighting was not great and the lens improvements were made to at least help a bit. I remember upgrading my ‘93 Vision Tsi to ‘97 headlight housings to get this small improvement. Hope this info helps!
I bought a pair of Phillips X-tremeVision bulbs to replace my older dimmer, but stills working bulbs. I forgot that my driver's side headlight had been cracked and broken years ago at it's mounting spots. At the time, I repaired it with epoxy putty and zip ties. I had bought both sides new back in 2007 for like $50 a piece.
Seems like the pre-1996 headlights can be had for a decent price, but the 1996-7 headlights are much more rare and cost a lot more. It will probably be more economical to work with what I have.
The T-15 screw that goes through the middle of the bracket and into the top of the headlight is missing. I'd like to put a replacement screw in place. I looked in the parts catalogue, but I don't see it pictured. It may be a long shot, does anyone know what size screw it is?
I'm currently looking for replacement headlights at 4WheelOnline. My current headlight is dimming and it is not as efficient to use at night as it used to. Glad I found this thread because I might have a problem in determining the sizing and mount.