Condensation in Headlights - Chevy Cobalt Forum / Cobalt Reviews / Cobalt SS / Cobalt Parts
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post #1 of 12 (permalink) Old 09-15-2013, 10:47 PM Thread Starter
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Condensation in Headlights

I'm getting water/condensation in the headlamp, passenger side. I did a search and apparently this isn't uncommon. A few folks replaced the headlamp and there was one thread with a link to how to take the headlamp apart.

I'm wondering whether the leak is from around the opening for the bulb or is it more likely that it's the joint between the clear lens and opaque, back part of the headlamp assembly. One post recommended taking the headlamp out and putting it in the oven as a way to reseal it. Another recommended putting more sealant around the joint(s).

Has anyone had success with sealing up the headlamp? Should I just try to re-seal it or just replace it? TIA

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post #2 of 12 (permalink) Old 09-15-2013, 11:36 PM
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I'd just reseal it with extra sealant. I used OCI Butyl to seal my retrofit. To get the best seal, you should bake them and pull them apart before adding the sealant and resealing them.


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post #3 of 12 (permalink) Old 09-16-2013, 06:43 AM
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I resealed my old cars headlamp by just getting a waterproof sealant and putting it around the edge of where the lenses starts.

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post #4 of 12 (permalink) Old 09-16-2013, 09:29 AM
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You really don't have to put it in the oven. Just leave it out in the sun until the condensation is gone. Then reseal it.

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post #5 of 12 (permalink) Old 09-16-2013, 11:21 AM
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If you look on the backside of the housing of your headlamp assembly, you will notice that in one spot, there is a slight bulge box shape. Take a small 1/4" bit and drill in just about a 1/4" inch. It will take up to a week, but your creating a weep hole for condensation to release out into the atmosphere.

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post #6 of 12 (permalink) Old 09-16-2013, 01:20 PM Thread Starter
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Thanks all for your suggestions.... it seems to me the easiest approach would be to remove the lamp and add more sealer to the seam. I might try pumping some air into the hole where the bulb goes and brushing some soap over the lens seam to try to locate the leak.

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post #7 of 12 (permalink) Old 09-16-2013, 03:41 PM
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Originally Posted by keegs View Post
Thanks all for your suggestions.... it seems to me the easiest approach would be to remove the lamp and add more sealer to the seam. I might try pumping some air into the hole where the bulb goes and brushing some soap over the lens seam to try to locate the leak.
Is it on the upper portion of the headlight towards the turn signal? I had the same issue, drilling the hole helped best. RTV sealant didn't do a licking of good. That's what OEM uses. If you changed your bulbs recently, you basically sealed up the headlights with moisture in the air. I call it the artificial aquarium cause when its a cold damp morning, its an ecosystem in your headlight.

2009 Cobalt LS XFE U74
Mods: K&N Typhoon Intake, Option Cat-Back Exhaust, Cosmo Short shifter, Maxxim Ahead 17X7's, MPx shorty antenna, FE5 Strut/shocks, Tein S Techs, Moog endlinks, Moog spring seaters, ZZP shorty header, LSJ downpipe, LNF front grille
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post #8 of 12 (permalink) Old 09-16-2013, 10:00 PM Thread Starter
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Quote:
Originally Posted by 5t3alth View Post
Is it on the upper portion of the headlight towards the turn signal? I had the same issue, drilling the hole helped best. RTV sealant didn't do a licking of good. That's what OEM uses. If you changed your bulbs recently, you basically sealed up the headlights with moisture in the air. I call it the artificial aquarium cause when its a cold damp morning, its an ecosystem in your headlight.
Thanks 5t.. any speculations as to why the manufacturer wouldn't design this into the lamp?

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post #9 of 12 (permalink) Old 09-16-2013, 10:11 PM
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There is an opening that has a small screen on the top of the back part for this purpose, but I think the screen blocks most of the moisture from escaping, especially when they get dirty.


2007 Cobalt Ls Manual Coupe
Kenwood Excelon X996, RF T3 Components, RF Power 6x9s, Sundown Audio SA10, RF Power T600.4, Alpine MRP-1000, Kinetic HC-1800, Black headlights, FX-R HID 55W, Custom led tail lights, Led reverse lights, Airbox mod.
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post #10 of 12 (permalink) Old 09-17-2013, 11:16 AM
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Thanks 5t.. any speculations as to why the manufacturer wouldn't design this into the lamp?

You have to consider that all their cars are sold all around in different climates, you also have to consider, these manufacturers are set to make money the cheapest way they can. What better more than to seal up headlamps and make you buy another set from a dealership for incidents like this one?

Notice that some aftermarket company headlamps created a hole with a weep tube to allow moisture to drain out so your concern wont happen.

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Mods: K&N Typhoon Intake, Option Cat-Back Exhaust, Cosmo Short shifter, Maxxim Ahead 17X7's, MPx shorty antenna, FE5 Strut/shocks, Tein S Techs, Moog endlinks, Moog spring seaters, ZZP shorty header, LSJ downpipe, LNF front grille
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