I finally got around to adjusting my headlights tonight but I noticed the drivers side cut-off isn't as sharp as the passenger. I also can't seem to align the beams perfectly. I know the drivers side headlight was replaced at one point so could it just be some sort of manufacturing defect in the assembly or even the bulb?

The first pic is the drivers side (you can see the beam fade away to the right), second is the pass. and the last is both as best as I could adjust them.

 

Honestly they look find to me...They're not supposed to be perfectly straight, They step off to the left to keep from blinding oncoming traffic.

 

They're not supposed to be. Yours are normal.

 

I think he's talking about the cut offs aligning right and left - yes your headlight could be adjusted right-to-left a bit but it doesn't really matter.

 

Yes, I realize there is a step-up built in. The light output just isn't as powerful or as clear from the driver's side light. It's more centered where as the passenger's output has a wider, more proportioned range. You can see in the last pic how the light kind of falls off on the left but its fine on the passenger side. I'm probably just being anal, mainly because I can't see around corners as well as I can in my friend's car, but I just wanted to see what you guys thought.

 

Well first of all.....your bulbs are old. After 1500hours hids are only 50% of their original brightness. The easiest way to align is to cover up each light with a heavy blanket to get a real idea how the lights blend together.
25ft from a wall, the top of the passenger side cutoff should be 2.1inchs below the center of the headlight and the driver side should be slightly lower just as a guide to follow.

 

Those are my old bulbs before picture I swapped just for reference those have about 1000 hrs on them

 

Just sent my headlights to customlightz for clear lense change and adjust the color and cutoff line. Can't wait till they come in