Where is the tab broken? Did it have anything to do with the headlight aim or overall stability of the light as you drove? If not, then insurance is just looking for an out to not pay for it.
If you can make an argument that the broken tab does not violate any structural integrity of the headlight, then there's no reason why they shouldn't replace it. Plus, go ask a shop if that would cause you to fail inspection.
Most insurance adjusters are ****ing stupid when it comes to cars. Don't get me started on one my friend was telling me about that had no clue what a "decal" was, and kept saying it was "necessary to replace for the car to be in running condition."
Last edited by Zell; 11-13-2012 at 04:14 PM.