Minor crashes can result in big headlight repair bills

Low-profile hoods and bumpers look sleek but leave expensive headlights vulnerable to damage in even minor fender-benders.

As part of its headlight evaluations, IIHS gathered price data on original equipment manufacturer (OEM) headlights. Replacing just one front headlight on two-thirds of the good-rated vehicles costs more than $1,000, far exceeding the typical insurance deductible of $500.

All of the good-rated headlights are LEDs or high-intensity discharge (HID) lamps, which are more expensive than traditional halogen headlights but more energy-efficient.

Prices for an OEM headlight range from $526 for the Subaru Legacy and Outback to about $3,200 for the BMW 5 series.

This is the case for headlights that rate poor, too. For instance, a poor-rated halogen headlight on the Mercedes-Benz GLE-Class is $615, an LED on the Honda Civic is $826, and an HID on the Chevrolet Silverado is $1,295.

Headlights consist of a molded plastic assembly that includes a housing, reflectors and a lens, and most are designed to fit just one model of vehicle. Even though bulbs or LED units and power modules can usually be replaced when they wear out, if any part is damaged the whole headlight generally must be replaced.

"Repair costs for a minor crash could easily double if a headlight is damaged," says Sean O'Malley, senior test coordinator at IIHS. "Not to mention the extra time your car will spend in the shop getting fixed."

The Institute's experience with one automaker indicates that manufacturers have wiggle room when it comes to setting prices.

"When we did an initial survey of prices last year for 2018 models, Ford was charging $4,555 for a Lincoln Continental headlight, the most expensive one in our survey," O'Malley says. "We let Ford know the price was out of line with other manufacturers. This year that same headlight costs $1,667."

Expensive headlights aren't a new issue. The Institute's bumper test program has highlighted the problem since the 1990s. In tests of 2007 midsize luxury cars, for example, it cost $847 to replace the HID headlight on the Infiniti G35 and $1,046 for the one on the Lexus ES, not counting installation fees.

Stronger bumpers could help protect not only headlights but also other front-end equipment, such as radar sensors and turbochargers. Reinforcement bars that extend far enough outward beyond the frame rails to protect the front corners of vehicles would help to limit damage to headlights in low-speed crashes. Bumpers that are taller and higher off the ground also would help.

Prices for an OEM headlight assembly