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Driver's Lens - with condensation
Internals to driver's side low-beam
Cap to driver's side low beam - with silicone in place
Internals on passenger side - for comparison
First post to the forum, and a new member so if this is a repeat of something previously covered I can only offer 1,000 apologies!
'05 Aero MT with condensation in AND a non-working driver's side low beam headlight. I have pulled the covers/bulbs multiple (3) times and used the shop-vac method of drying the lens out, but each time I do it just fogs up again. As you can see from the images, a previous owner took a shot at doing some sort of mod to the lamps, and then punted and just cut the wires as a way out. I took the liberty of filling the gap between the gasket and the cover with silicone as I thought this was an obvious avenue for water to get in, but no change. Maddeningly, it is only the driver's side is full of moisture and NOT the passenger's side to boot - and BOTH have the same mod to the low beam cap... After the most recent drying out of the lens, I also replaced the low beam bulb and checked the fuses (they're ok) with no change in outcome so now I'm at a loss for what to do!
At this point, the lens will fill with condensation just sitting in wet weather - I don't even have to drive it...
Thoughts?
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It seems you will probably need to bake your headlights and reseal them. There really is no other good way to get all that water out. I have tried using large rice, the shop vac method, and everything else under the sun...the only real fix was the baking method.
Since I was probably the first one to do this mod on the board, I will chime in. Here is the original link to the post I made regarding headlight modifications: http://saab92x.com/viewtopic.php?pid=82150#p82150 . Let me know if you have any questions. This is obviously a last course option, but it isn't too hard and will definitely cure the problem (as long as you reseal it properly and make sure to seal the wires in well too). It just takes a little 'cojones' to put your headlights in an oven.
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I had a little condensation in one light, and tried several things to get it all out. In the end, I left the cap off for a few hours on a warm sunny day and that was enough to get rid of all the moisture. Much easier than taking out the whole assembly and trying to use a heat gun on it. I wish I would have just done that first.
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If you have not fixed the underlying problem (the leak), the condensation will come back.
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