Thanks for all the replies.. I traded in and 07 Acura with projector HID headlights for my BMW.. Never had this type of issue with the Acura!.. I can tell you as a Quality Assurance Professional, the design on my X1 headlights is ****!
I'm about ready to take the car back and go back to Acura!
Have ridden in a 2013 Cadillac SRX with adaptive HID headlights, and that AMERICAN engineering and quality seems to be much better.