Well almost....
Take your time with it.Turn the bolt slowly and just a little bit and move the headlight every now and then.Sometime sand can get into the box that the headlight fits into and then makes the headlight stick.As you turn it slowly try to pull on the headlight lightly.It is kinda hard because the way the angle of light housing is made so try using one of those shelf pads that keeps things from moving around if you have that.once you break that grit up it should finally start to move foward on it own.Hope that helps some.
Just gave me a fresh new found sense of energy, as I was going to bed, and checked my email one last time. Worth noting that I didn't get involved at all today on the T-Reg until just now, close to 1:00 A.M....here's what happened.
So the WD-40 has had over 24 hours to soak in, particularly on the frozen stiff hex bolt on the passenger side. So I popped opened the hood immediately after reading your quote, SHOOK and pushed both headlights like a madman(literally), and started with the side(passenger), that has given me the most grief. The frozen stiff hex bolt on the passenger side. Well guess what!!! The bolt moved!! I barely even put pressure on it! I spun her a bit more, and wouldn't you know it, the headlight slid out a few cm's like butter!!!
So I pushed the headlight assembly back in, tightend the bolt back in the "close" position, sprayed some more WD-40 for good measure, and moved on to the drivers side, with some new faith. Unfortunately for this one though, it was still exhibiting the clickety snap/POP sounds, as I would spin it, like something(teeth?) was slipping down below. I can't for the life of me figure out what is slipping and making all that racket down there. Anyways, basically nothing has changed with this one. I tried pulling on the headlight, with the minimum edge clearance, between the fender edge and headlight assembly, allowing my fingers to hold on it(wore sticky plastic gloves for more grip), and as I twisted the bolt, right before it would go snap again on me again, pulled on the assembly at the same time....but nothing
I sprayed some more WD-40 on that one, closed the hood.
Tomorrow after work, I will give it my all. Interesting though. I never would have predicted this outcome. The side that I thought would be the ultimate problem, has now been solved, but the one that I figured would eventually give in to me, as it was never frozen to begin with(the hex bolt), is being the pesky one, and ultimately, the reason why I end up going to the dealer again. Well at least 50% is done. That's better than nothing.
Tomorrow is other day....