I finally got sick and tired of washing the car and having my directional bulbs blow as soon as I used them after the washing..

I have replaced at least 5 bulbs in the past year...

So I put her up on Rhino Ramps and got started... I removed the access panel in front of the front tire. Then that allows you to remove the 2 screws that hold the lens in.

Once the lenses were out and on my bench it was clear what had happened.. The bulbs get really hot and cause the plastic over the top of the bulb to melt and crack... Once the cracks are open.. Water drains inside directly on top of the hot bulb... POOF!




So I sanded the cracked surface to clean and roughen it up.. Then I used a small amount of (FASTSTEEL) Putty. You can get it at Home Depot. The rest of the lens would melt before this stuff would...

I kneaded it and spread it smoothly over the affected area and let it harden... Perfect.. Except for the powder fog that all over the inside of the lens and clouded it up. This fog is cause by the bulb blowing up inside the lens..

I shot windex inside the lens and swished it around real good and then rinsed it with hot water and Dawn detergent..

Now for drying.. I have a cool trick.. Shake all the water out that you can.. Then put the oven on 180 Degrees. Rest each lens on top of a pot holder with the bulb holes facing upward to allow the moisture to exit..

Bake for 30-45 minutes.. Viola.. perfect...
In this picture you can clearly see the Cracks and the FOGGED Inside..


Here is a shot of the cracks from the inside...


Here is a shot of the finished and sealed lenses..

 

sweet, you got more b@11$ than i do to try that. mine kept burning out too the dealer replaced a seal that was bad, now it does not happen anymore, so far anyways. Great writeup and glad it all worked out for ya.

 

Not sure what seal they are talking about... The only seals are the rubber gasket around the bulbs.. They most likely replaced the entire lens and never told you that their crappy design was burning the lenses...

 

Just curious... Other than LED lights.. are there any LOW TEMP bulbs out there to replace these with ?

 

maybe a lower wattage bulb with the same base would work
or possibly put a vent hole in them to vent the excess heat buildup??
(probably have fogging problems with the vent though)

 

No the Vent hole would not work.. That is where the cracks occur and let water in..

 

i was actually talking about venting it on the top corner of the light away from the bulb heat will find its way out as long as its in the top of the light (heat rises theory)

 

Good theory..actually.. And it would probably work.. But any vent on the top would be prone to water leakage..

 

hence another hole in the bottom of the light for drainage only smaller than the vent hole

 

Yeah I guess but the fogging up would be an issue.. Vents and all... any moisture in side the lens seems to adhere right to the face of it..

Better to just keep it sealed..