[Mark_T]

It seems that each time you try something the symptoms change, but the common denomiator is that each time you make a change you remove and replace the headlight assemblies. That would point the finger towards the connectors, as you suspect.

If you remove your inner fender liners you will have clear access to those connectors from the back side, and you can check to make sure they are fully engaged.

Removing the headlight tray is just a matter of removing those three flat brass nuts and then lifting it off. Pull it forward and you will have better access to the yellow retaining clip that holds the connectors. Don't mess with the assemblies beneath those brass nuts or your headlights won't line up properley in their holes anymore.