Headlight Condensation Solved (?)

[2013megacab]

I may have found the problem causing headlight condensation. Some time ago I got some condensation in the passenger side headlight. Somewhere I found a post about people pulling headlights, drying them out, and putting desiccant bags in them. Another post said there was a TSB about improperly assembled headlights. There are three vents at the rear of the headlight that are designed to let the heat from the headlight drive the moisture out and some were assembled with the protective caps on so tight that the moisture couldn't escape.

After thinking about it I decided against the desiccant. If moisture is getting in and not getting out, you will ultimately get condensation no matter how much desiccant you put in. So I just dried mine out, made sure the vents were correct, and reinstalled them. I got more condensation.

Thinking maybe I didn't get all the moisture out I tried again. This time I made sure there was no more water in the unit. But I damaged the yellow lens on the side by letting the unit get too hot from the hair drier I was using. It didn't matter how hot I got it; I still got more condensation in the unit.

One more try....I pulled it again (I'm getting pretty good at this now). This time I pressurized the unit with a vacuum cleaner and doused it with soapy water at every seam and joint. No bubbles. So the only place for moisture to get in is the vents or, wait for it, the back cover which I pulled off to dry and pressurize the unit.

I used some butyl tape, the kind used to bed glass in windows, and added it on top of the gasket on the back cover. It has only been two days, but before I had condensation the next day, and I have no evidence of condensation.

So if you have condensation in a headlight, pull it out, remove the vent caps, remove the back cover, hold the unit horizontally as it would be in the car and rotate it backwards to allow any liquid water to drain out the opening in the back. Hook up a vacuum cleaner with the hose on the output of the cleaner instead of the input or use a hair dryer on a LOW setting and let it run for several hours. Check it periodically to ensure it doesn't get too hot. When dry, let it cool down and reassemble it. Put the vent caps on so they just stay in place. Do not push them until you can't push them any more. Get some butyl tape from a window place and use it as an additional seal on the rear cover. Then cross your fingers and hope it works. That's much cheaper than a new light.

Al

 

[Cummins12V98]

My son had his Limited headlights replaced under warranty.

 

[2013megacab]

Maybe I should have argued with my dealer. I don't know if it makes any difference, but I'm in my MaxCare now, not the original warranty. After I prove this to be the problem I will have a discussion with MaxCare to see if they will give me a new headlight because the condensation ruined half of the turn signal LEDs.

Al

 

[Dasmoeturhead]

Maybe I should have argued with my dealer. I don't know if it makes any difference, but I'm in my MaxCare now, not the original warranty. After I prove this to be the problem I will have a discussion with MaxCare to see if they will give me a new headlight because the condensation ruined half of the turn signal LEDs.

Al

After I did this procedure the next day the condensation was back. The truck sat in the warm garage overnight.
After that it hasn't re-appeared in over a week, but then again I haven't driven it that much. My vent caps were pushed in all the way from the factory.

 

[2013megacab]

I had a similar result. After a couple of days there was some light fogging, but not nearly as bad as before. Some night driving with headlights on and it cleared up. Several more days now, with no significant rain, but no condensation. It has been driven a lot so if the moisture was coming from the engine area, it isn't getting into the light any more. I'll post again after some rainy driving.

Al

 

[Lynx0849]

Thanks for that analysis.

My dealer suggested I pay them an outrageous amount for new ones. Not in warranty any more. They seemed surprised to see all the water.

How to remove them? I took out my gen 3 ones with much angst but this is a ‘15.

I see a door in the front fender liner.

I don’t like to my truck cry.



Pro

 

[Dasmoeturhead]

Behind that plastic door in the fender well, if you use a flash light you will see a white plastic clip. Push that up. Then there are 2 bolts on the front of the truck that need to be removed. Then just pull straight out, and wiggle it a little bit to remove. The bottom bolt is kind of way down there, and you will need an extension for your ratchet, and a 10mm socket. I used a magnetic socket. Another trick for that bolt would be to stuff a piece of electrical tape in the socket, then when you put the socket on the bolt head it fits tight and will aide in bolt retention.

 

[2013megacab]

I'm sorry to report that the condensation is back. I have no idea how water is getting into the headlight. I bubble tested every seam, port, and connector with no indication of any leak. The only thing I can think of is that there is something about the vents that is supposed to keep water out and it is not working. Obviously I ignored any bubbles from the vents because they are supposed to let air out of the housing.

I guess I have no alternative now but to replace the headlamp assembly.

Sorry if I misled anyone. It has take longer than before but it is obviously still leaking somewhere.

Al

 

[Dasmoeturhead]

Sounds like you did everything that you could have, most people whould have just bought a new one. That's how our throw away society is these day's.
Having to buy a new one after all that just stinks.
I did mine the same as you did, and so far its working, but I haven't been in the rain yet. Well a little bit but not really a soak test.
The only way I see to do it, is to break the seal, but I bet I'd never get it to seal again. I'm sure a new assembly is in my future also.
Good luck Al, hope you can find a new assembly at a reasonable price.

Tom