QUOTE(McKhaos @ Jun 28 2008, 07:14 AM)

Another theory is : I run around all day with my lights on (it's the law) and the headlight washer comes on at the same time with the windshield wipers. Do that 5-6 times a day, 2 years straight and the casing will crack from the thermal shock (heat from the sun + lights vs. coolness form the washer fluid).
Its possible, but your washer solvent absorbs the heat of the engine bay as your driving. When its sprayed, its pretty warm, although with the alcohol content it flash evaporates very quickly and could cause the cracking. The only reason why i dont think that this is the cause though is there are many plastic lensed headlights with washers on them that dont show this kind of behavior.
Is the car under a factory warranty? If so, the fact that there is no impact damage, and both headlights exhibit the same fracture could easily get them replaced.