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I am facing the same problem with my 2003 Beetle. Some have suggested drilling a smail (1/16") hole in the slider and using an awl to move the slider lock up. Others on a model year I don't recall, removed the assembly to get into the slider lock assembly. Good luck!

See also: http://www.cindyli.com/index.php/site/comments/vw_beetle_headlight_replacement/

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Q: How do you replace headlight for 2000 Beetle if you broke the lever to unlock the headlight?
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