Unless I'm misunderstanding the OP, it seems like it is more of a senor issue. Even when my plastic adjusters were shot to pieces, my auto-leveling still worked every time I started the car, it's just that the light beam would be aimed low. If you don't see the lights adjust when you turn the car on, I'd make sure you have a good connection on everything you unplugged to do your work, check the fuse, and if you're still having problems check your leveling sensor under the front of the car by the passenger front tire.
Odds are that after 6 years your plastic headlight adjusters are probably shot too though. The OE plastic pieces they used are just crap. If you do end up replacing them definitely do the aluminum ones so you don't have revist that again.
Last edited by resharp001; 10-20-2009 at 03:59 PM.