So I got a 3 year old oem headlight getting condensation. No cracks I can see with my eyes. I decided to pull the cover apart and reseal it with butyl from TRS. It worked for 2wks but came back again. So I tried baking it again and pushing it together to get a good contact.(I hope). Again everything is good for a few weeks and it is back. Any tips? I double check all rubber seals. Clueless at this point. Thanks

Maybe a poor seal on the bulb? Swap bulbs left to right and see if the problem follows the bulb.

I did that and still the same. I pulled other bulbs I had laying around and stuck them in. Same. Sad. The headlight still look new too. LoL

you have a weak seal, check the corners, especially the outside edges. and all screw holes.

I had the same issue a little while back. Bought some gorilla sealant, worked like a charm. Might be something to check out

I did an inhumane thing.

I ran silicone around all the edges/gaps on both headlights.

Thanks for the suggestions. Will try again lol

I would buy new O-ring seals for the lamp sockets on the headlamp assembly from Toyota and install them. If the they are old , dry cracked , shrunk or do not fit snug , it could be your issue.

This how I repaired mine as well. Used a hair dryer to drive the moisture out and ran a bead around the seal. Done, and done.

Not always... I’ve been chasing this issue with some aftermarket ‘06 projectors that I bought from Amazon for far too long now. I very carefully silicone sealed the driver’s side that started leaking a few months after they were installed. It was good for maybe a month, but once that side was fixed then the passenger side started. I did the same fix to that side, then a few weeks later the driver’s side started again! During the many times these have been out, I was super careful to use a Teflon based o-ring sealant on all the bulb sockets just to be certain it wasn’t originating there. At this point, I’m perplexed and beginning to think that maybe the vent is somehow defective and letting moisture in since I can honestly find no other way it can be entering at this point. At this point, I’m ready to just shitcan these, or sell them to someone looking to do a real projector retrofit or something and move on to some factory Sport ones. I like that my aftermarket ones are flat black on the reflectors, which looks awesome with my black truck, but I’d settle for the smoked Sport ones just to have clean looking lights for once!

I'll get it split apart again and try a thicker bead of the rubber butyl but this time I'll use some ratchet straps but carefully. I do notice just right inside the bulb housing I see some brown stain. Not crusty but looks rusted. Don't know if that's normal or what. I remember my old oem housing non projector had the same problem on the same side.(weird) Split it apart and re-seal. No issue. Which is why I still have leftover butyl. So frustrating

Guys, before even i proceed with "sealing" headlight, does anyone have any idea how to clean-up all that "watery mess"?
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Clr?

I pulled the low and high bulbs out. Stick a blow dryer to the high beam socket and waited. Eventually, they'll dry up. Heat the plastic from the outside helps too.

That’s how I’ve usually done it, but in addition to that, I’ve taken along section of paper towel and twisted it into a diameter that can fit through the bulb hole making sort of a wicking rope to dry the puddles first. Usually I bring it in the house, flip it glass side down for a short time so the water pools. That makes it easier to wick up the bulk of it, then I use the hair dryer to evaporate most of the remaining moisture. It still helps to leave it in the house at least overnight to continue drying out. I run a pellet stove for heat this time of year, so I leave it near that, which helps a lot. I just wish I didn’t have to keep doing this! At this point, short of permanently sealing around the bulbs with silicone, and blocking the vent, I’m out of ideas. Who knows, maybe the adjusters need to be sealed too. Wish I could trash the vendor on Amazon, but they won’t allow me to post a review for some reason...hmm... wonder why that is...?