I've got an '03 that has had condensation issues in the passenger headlight ever since I got it ( about 2 months)
I waited a bit too long and the lamp quit working so I ripped it apart last weekend to find I had a ballast full of water that was fried.
I followed the instructions for clear corner light diffuser installation and everything went great. After a couple of car washes I've got condensation only in the passenger headlight ( which was the second one I baked, and IMO the better sealed of the two I did)
While I'm not completely ruling out the possibility of it being an issue on my resealing job, I'm much more anticipating an issue with one of the bulb sockets not being sealed, or one of the vents having issues.
I've got to rip the headlight out to replace the ballast here hopefully this weekend, so just looking for a few ideas on what to hope to be my problem.
I'm 100% confident it's not an issue with the seal on the HID bulb cover or the high beam cover/bulb seal.... more or less interested to see who has had issues with either turn signal bulb/side marker allowing condensation in, or if it may be a problem with one of the vents.
( PS, the tires look huge because they're studded snow tires )

Thanks to the creative members here and elsewhere, I came up with these....


( pre lens cleaning)


I should also mention that the wash I've been running has an under carriage blast in case that matters.... I don't think it should, since it has never affected the drivers side assembly in the 2 months that I've had it, and the fender liners etc. are all intact.

Any thoughts and suggestions would be appreciated.

 

Any suggestions on what to look for with a headlight still leaking after being resealed?

 

Are you sure you got all the moisture out before sealing?

 

Diffusers look good! Are you saying you run your car through a car wash?! If so that's a big no no. Hand wash only...

 

Yep, I used a blow drier for a few minutes on both lamps, and both were crystal clear going back in the car. The driver's side is still clear, but the passenger side slowly started to fog up over a few days.

Thanks on the diffusers.
Where I work there's a wash ( and I'm a mechanic ) initially I was worried about taking it through, but my boss has been running his soft top jeep through for years without any issues. I figure the car wash isn't supplying anything the car wasn't designed to handle while driving 70-80mph down the interstate in the rain, am I incorrect in this?
We have people with soft top convertibles go through the wash all the time.... worst thing that happens are a few water droplets make it past the seals but nothing major.