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Q:

Should a chipped windshield be replaced or filled?

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Your insurance company will probably fill the chip for free. If not, then repairs are usually very inexpensive. Have it filled and then give it a month or two. The appearance of the fill changes over time. Then, if it's still driving you nuts, replace your windshield. I've had smaller chips repaired, and while it was noticeable immediately after the repair, a year later I can barely find the spot.  more

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I've had chips filled by one of them major car-glass companies. Can't remember which one -- might have been Safelite, actually. Anyway, it was still a little bit visible afterwards, but much less than the chip was before. I don't think it would have been worth replacing the windshield because of it. Unless you keep a very clean windshield (and I'm pretty OCD about mine, or so people tell me; I go through washer fluid almost as fast as I do gasoline) you probably won't notice it too much. Unless the chip is directly in your line of vision, I'd get it filled. Even so, your insurance company may not give you a choice -- mine didn't. They had some standard (less than 1"?) under which they filled, and over which they replaced.  more
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A 'chipped' windshield can be filled in by a local windshield repair shop, but if it has spidered, than you are looking at a whole new windshield.  more
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IAAIA (but I'm not your insurance agent, so naturally YMMV). This is a covered loss, as long as you carry Comprehensive insurance. In most states, GEICO uses Safelite. According to their <a href="http://www.safelite.com/repair.jsp">website</a>: "A quality windshield repair will restore the structural integrity of the windshield, help prevent the damage from spreading, and make the blemish much less noticeable, without removing and replacing the glass." I'm not sure how well that will mesh with your OCD, but most companies should be able to make it almost imperceptible. Your profile doesn't mention where you are, but in certain states, you can elect to have your Comp deductible waived for glass, so check your policy. In other states, your Comprehensive deductible is waived automatically (without your having to select the waiver up front) for replacement or repair (i.e.: here in Florida, it's illegal to drive around with a chipped or broken windshield, so the insurance company absorbs ...  more
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I have three repaired chips on my windshield. One is nearly invisible, and the other two are rather obvious. The glass place should be able to tell you how visible it will be, and whether it will pass safety inspection in your area.  more

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