Although I have not run across this problem yet, as this is old news, but a fellow headlight restoration company “M & J's Headlight Restorations” located in Towson, Maryland is still finding cases of the 2003 – 2007 Toyota Highlander HID daytime running light / High Beam light bulbs overheating and melting the headlight lens and lens casing. M & J's are leaving notes on the vehicles they see while out & about that appear to have evidence of this issue. You can read more about their ongoing research and view photo's here.
I looked up some more information on this Toyota Highlander Headlight issue for those of you who either have or know someone that has one of these vehicles.
Auto Recalls For Consumers:
To File a complaint about a Vehicle issue:
Hope this information helps someone.
By Scott Summerson