Continuing Headlight Moisture Problem

[2013megacab]

I am continuing to have problems with moisture in my passenger side headlight. I have pulled the headlight several times, drained the moisture, dried it out with a hair dryer, pressure tested it for leaks and found none but after a couple of months I now have around an inch of liquid water in the bottom of the headlight at the lens. I find it hard to believe that this is the result of atmospheric moisture being drawn into the headlight and condensing.

Does anyone have any idea where this water might be coming from? I thought it might be from the cooling system but as best I can tell I'm not loosing any water.

I'm reluctant to buy a new headlight unit and have it ruined too.

Thanks,

Al

 

[BarryG]

I may be wrong but thought I had read some where that there is a vent/s for the headlight so that condensation has a harder time to develop and help dry it out when it does occur. If so could it be plugged/pinched. However an inch of water in it sure seems like a lot. If it is sealed well as you found by pressure testing how could it be anything but condensation

 

[2013megacab]

Thanks for the reply. There are three tubes on the rear of the housing covered with soft plastic caps. The top of the tube has some kind of a screen. There was a post on here or another forum that said there was a recall for the caps being put on wrong at the factory. I corrected that the first time I pulled the headlight and made sure they were right on the two subsequent pulls. I don't know what the screen-like thing is. Maybe it is letting moisture in but not out.

 

[Cummins12V98]

Under warranty they WILL replace headlights with this issue.

 

[2013megacab]

Thanks - I was tole that MaxCare doesn't cover condensation.

 

[Bob4x4]

There is a test for condensation,it involves running the truck for a set time with the lights on.An inch of water will not dry out with just the heat of the lamps

 

[Lynx0849]

Rather than start a new topic, what too is required to adjust the headlights?
I can’t see in the access holes.

 

[Dasmoeturhead]

After taking mine apart twice, I believe I fixed it finally. I used RTV to compleatly seal the the housing to the lens once I had the water dried out. So far I've been 5 weeks of no condensation, and I've been on a couple of long interstate runs during major rain events, and still no condensation.

 

[2013megacab]

After taking mine apart twice, I believe I fixed it finally. I used RTV to compleatly seal the the housing to the lens once I had the water dried out. So far I've been 5 weeks of no condensation, and I've been on a couple of long interstate runs during major rain events, and still no condensation.

Thanks! I checked my MaxCare warranty and it does not cover lenses. I suppose I could argue that this is a housing, not not a lens, and I may try that before drying it out once more and sealing it, but I will take your approach if I can't get it replaced.

Al

 

[Dasmoeturhead]

I feel your pain Al. I did pretty much the same as you did, but like I said I,put a bead of RTV around the lens to housing seal, and so far so good. Here's a crappy cell phone picture of it.

 

[Hippy43]

I feel your pain Al. I did pretty much the same as you did, but like I said I,put a bead of RTV around the lens to housing seal, and so far so good. Here's a crappy cell phone picture of it.View attachment 109887

Now I read this.
Weather finally got nice enough to remove my drives side light and believe it or not, I damned near filled a red solo cup with water from my housing!
WTF?!?!?
Dried it out all nice and clean, reinstalled, checked breather holes, thought I was in great shape,,,, until the rain and fog moved back in and now I'm back collecting moisture.. Picture attached was taken about 2 months befor eI did my drain and dry.

This is a royal PIA but next time I dump it I'll see if the RTV around the seal helps..

How's yours holding up?

 

[MCSloan]

Had same problem w/right headlight Drained water & dried out. Checked seal around lens & found poor sealing. Sealed all around lens w/silicone. Have been in heavy rain several times & all is well.

 

[Dasmoeturhead]

Now I read this.
Weather finally got nice enough to remove my drives side light and believe it or not, I damned near filled a red solo cup with water from my housing!
WTF?!?!?
Dried it out all nice and clean, reinstalled, checked breather holes, thought I was in great shape,,,, until the rain and fog moved back in and now I'm back collecting moisture.. Picture attached was taken about 2 months befor eI did my drain and dry.

This is a royal PIA but next time I dump it I'll see if the RTV around the seal helps..

How's yours holding up?

View attachment 111223

It's still clear of any moisture/condensation. Guess I got lucky. I had my headlight assembly on the work bench 3 times before I got it right.

 

[MCSloan]

Mine is still holding. Factory seal looked pretty bad. Has been a month or better & have driven many miles in heavy rain.

 

[Dude's Diesel Performance]

After taking mine apart twice, I believe I fixed it finally. I used RTV to compleatly seal the the housing to the lens once I had the water dried out. So far I've been 5 weeks of no condensation, and I've been on a couple of long interstate runs during major rain events, and still no condensation.

This is what i have had to do on multiple aftermarket headlights i have bought. I know yours are stock but still same concept. i always seal them entirely before installing never had an issue again. Might be worth a shot.

 

[MRoberts]

A couple of years ago I had a local stereo and lighting shop install an HID system in my truck, it was more out of convenience than lack of ability. Note to self: NEVER GO CONVENIENCE ROUTE AGAIN! The light output was great, but I never felt comfortable with the lights and was really worried about failure. So I decided to take a look at them. Keep in mind, they had worked fine for two years and I only had one minor moisture issue after a a couple months. The install shop fixed it.

I was (still am) so pissed when I saw the backside of the headlight assemblies! Butchered is putting it mildly, you be the judge!
Both sides look virtually identical.

Duct tape! A "bonus" hole! Melting! Enough sealant/adhesive to fix everybody leaks! Searching for new cover plates, have a few leads at some salvage yards. I'll pay $$$ if someone has any available!

 

[Hitec.Redneck]

My 2014 has some condensation in the drivers headlight. I guess my next job will be to remove it and seal it. Thanks for posting the pictures, it helps.

 

[Hippy43]

Well, the turn / park LED's in my replacement drivers side headlight finally completely died last week.
This is the one I bought just a little over a year ago for my broken, bird strike headlight.
https://www.amazon.com/gp/product/B01FHZDL8U/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

I was really upset it finally died as I've had it in and out three times now to drain water.
I finally called Amazon support, little help, who gave me the original manufacturer, (https://www.genera.com/) who was very nice to point out that they (Genera) are only the manufacturer but AMAZON is the distributor and ALL of their products are covered for LIFE (https://www.genera.com/Warranty-Policy.html), how cool.
Well BACK to Amazon and after getting bounced around by india support I demanded a USA rep.
Got hooked up with a nice young lady (Carrie L) who, after explaining all of the hassle and no matter what Amazon says, the actual product does carry a 100% lifetime warranty.
A little time on hold and she comes back to tell me that her boss's agree (after a conference call with the Genera rep) that Amazon owes me a headlight.

Hopefully all is cool and I'm now just waiting on the delivery.

I'm still so pissed about this condensation thing. Headlights are WAY over priced and there is no way to replace the LED's when the moisture finally kills them.

If anyone ever finds a good deal on replacements,, please let me and everyone else know.

Might be worth keeping a spare around.

 

[CEppinger]

No condensation problems thankfully, but they are the worst when it comes time to replace a bulb (should be simple but you have to remove 11 screws!).

 

[Hippy43]

LOL, agree but even though it should be easier, we've (my wife and I) gotten it down to 20 minutes or less to R&R the headlight.