Attention: TDR Forum Junkies 
BigPapa
TDR MEMBER
I recently polished my yellowed headlight lenses and noticed the right hand light was still cloudy but not yellowed. Upon further inspection there was moisture on the lens and looked to be on the reflector. I had this happen to me on my '95 and did this same procedure, just didn't take pics, so maybe this will help someone else down the road.
After removing the headlight assembly and carefully inspecting where the lens mates to the reflector, you can see where the lens is starting to separate from the reflector. On the three assemblies I've seen this happen to, it has been on the bottom of the lens.
I carefully insert the sharp edge of my knife into the gap and gently pry it side to side enlarging the gap. Continue this around each corner, then the ends, then the other corners, and finally the other long edge.
Take note, the edges on the ends that mate together are not straight down but at the same angle as the ends of the lens, so you will need to pull the lens away from the reflector at that angle.
This will allow you to totally separate the lens from the reflector.
Before re-attaching the lens use a soft lint-free cloth and some good window cleaner to clean and dry the inside of the lens and the reflector. Make sure to remove the lamp before spraying any window cleaner on it just to be safe not to "contaminate" the lamps surface.
Once you've cleaned everything good, apply a THIN layer of silicone evenly into the groove where the two edges mate together. Put the pieces together and let it set up good before putting the light back on the truck.
I have had success with this procedure three times. It's not hard and as long as you realize the angled edges on the ends it would really be hard to break anything.
Good luck!
After removing the headlight assembly and carefully inspecting where the lens mates to the reflector, you can see where the lens is starting to separate from the reflector. On the three assemblies I've seen this happen to, it has been on the bottom of the lens.
I carefully insert the sharp edge of my knife into the gap and gently pry it side to side enlarging the gap. Continue this around each corner, then the ends, then the other corners, and finally the other long edge.
Take note, the edges on the ends that mate together are not straight down but at the same angle as the ends of the lens, so you will need to pull the lens away from the reflector at that angle.
This will allow you to totally separate the lens from the reflector.
Before re-attaching the lens use a soft lint-free cloth and some good window cleaner to clean and dry the inside of the lens and the reflector. Make sure to remove the lamp before spraying any window cleaner on it just to be safe not to "contaminate" the lamps surface.
Once you've cleaned everything good, apply a THIN layer of silicone evenly into the groove where the two edges mate together. Put the pieces together and let it set up good before putting the light back on the truck.
I have had success with this procedure three times. It's not hard and as long as you realize the angled edges on the ends it would really be hard to break anything.
Good luck!
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