Well way back when, when all of arguing was going around about whether this could be done I said I would do a how-to the next time I performed it. Now that I'm working on building an add on to allow installation of projectors into factory housing I've been taking apart a number of headlights. So here you are...
-Pair of gloves, mechanic gloves worked fine for me
-T10 torx bit or torx screwdriver
-7mm wrench (if you plan to take entire headlight apart)
-Multiple flat head screwdrivers (I mainly used two a small length #1 head and a medium length #2 head)
-2 flat cookie sheets or equivlent
-Standard kitchen oven
-High temp black silicone RTV
-4 wood clamps, 2 for each headlight
Step 1 - preheat oven to bake at 275 deg F
Step 2 - Remove all rubber, plastics and brackets as possible to prevent possibly melting and ease handling. This includes mounting brackets, weatherstripping across top, bulb retainers (T10 Torx), rubber seals and vent hoses.
Step 3 - Place headlight in oven and set timer for 3-4min. Remove headlight promptly after this time and begin prying lense away from housing. You will need to repeat this step multiple times until the lense is comes free from the housing. This process for me was repeat 4 times. Here is the progress from each reheat...
Round 1 - I was able to loosen the top of the lense from the housing. (I apoligize for the blurryness of this one shot)
Round 2 - The lense was loosen completely on the top and I unlocked all three tabs across the top as well.
stupid 10 image rule...