Is anybody else developing stress cracks on their headlights? Specifically the clear external polycarbonate cover?

I have an ever increasing number of stress cracks on my passenger headlamp, and just recently have started developing the same thing on the driver side.

Unfortunately the dealership won't cover it under warranty (like everything else). I've bought an extra headlamp assembly from the junkyard to swap out the cover myself, but obviously this can get expensive real fast.

I wonder if it's an issue with a particular year (mine is an early '07).

Call corporate. This is a defect in the materials. It has happened to many of us--maybe the 07's do have a problem with this. Like you, my passenger side was real bad and the drivers side showed only a tiny bit. I went to my dealer and they replaced the passenger side no questions asked. Unfortunately, they did not swap bulbs so I lost one Ultinon HID bulb and a Nokya yellow fog! In any case, I wanted the passenger side fixed before I blacked out the lights. It does happen to other makes as well. Look up "headlight crazing".

Thanks! I went ahead, crossed my fingers, said a little prayer and brought my lucky horshoe (well, maybe not that) and went in to the dealership.

I finally met a service advisor that was nice, friendly and very considerate. It was pretty much an in-and-out deal. He saw the problem (both headlamps, passenger being worse), also showed him the peeling interior trim and he went in and scheduled the car for warranty work/replacement.

Given that this is the third or fourth time i brought it up, only to be denied, i was extremely shocked and pleased this time around!

Looks like you got lucky there, i have same on my passenger lamp but i have overlays so the dealership will not be as considerate obviously.