Feel your pain! I bought a set of '05 takeoffs a few years ago for $200, followed the instructions and pulled them right apart but then made the mistake of putting the lenses back in the oven to soften up the glue. They frosted and melted like yours... Quickest $200 I've blown in a while, did "force" me to order a set on-line. Live and learn!
I did my 08's at 275 for 15 minutes each...just have to watch it closer....and use a glove lol but it worked awesome. I painted the surround and reflector in mine.
I have a set of 05-07's I'll let go pretty cheap. OEM headlights
On the older trucks, the adhesive is usually too old to soften when you bake them, so you'll need to carefully cut the headlights apart with a Dremel. I tried baking the lights on my '04 when I did a bixenon retrofit, but it did no good.
I resealed them back together using a clear silicone adhesive/caulk.
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