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E63 / E64 6 Series (2004 - 2010)
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  #1  
Old 08-29-2019, 12:56 PM
645CiGrrr 645CiGrrr is offline
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More 645Ci Headlight questions

Hi all,
I have corrected so many headlight issues I cant stand the thought of ordering yet another ballast or bulb for the rest of my life.
Question to the forum is how the water is reaching the underside of the headlight assembly.
I have replaced the lenses and sealed everything up the best I humanly can. I still get a very small amount of condensation on occasion but no big water issues yet the ballasts are STILL frying!
After a wash I feel around inside, seems dry, pop the back covers off, all dry...yet 3 months in on another new ballast and its toast.
Thoughts?
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  #2  
Old 08-29-2019, 07:34 PM
HerbP HerbP is offline
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There are seals on the bulbs that seal it to the headlight, have you replaced them?
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Old 09-04-2019, 05:18 AM
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Hsurf Hsurf is offline
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Another possibility is the gaskets on the inspection doors have compressed too much over the years and are no longer doing their job, you can either buy new ones or cut out a fresh gasket out of any material so long as it's 1-2mm thick using the original as a template, pop it in the doors then replace the original over the top, you'll find the doors slightly harder to close ensuring a tight seal.
Also make sure the breathers (two on each headlight) are free of debris, I had spiders make a nest in them, one the little buggers is still in there very dead but still there.


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Old 09-04-2019, 07:05 AM
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645/333 645/333 is offline
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Originally Posted by Hsurf View Post
Another possibility is the gaskets on the inspection doors have compressed too much over the years and are no longer doing their job, you can either buy new ones or cut out a fresh gasket out of any material so long as it's 1-2mm thick using the original as a template, pop it in the doors then replace the original over the top, you'll find the doors slightly harder to close ensuring a tight seal.
Also make sure the breathers (two on each headlight) are free of debris, I had spiders make a nest in them, one the little buggers is still in there very dead but still there.


Your taking a big risk as some jobs-worth will report you to the RSPCA for murdering a spider, boasting by leaving all the evidence they need
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Old 09-04-2019, 01:56 PM
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Hsurf Hsurf is offline
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Your taking a big risk as some jobs-worth will report you to the RSPCA for murdering a spider, boasting by leaving all the evidence they need
I didn't put it in there so as far as I'm concerned he committed suicide .
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Old 09-04-2019, 06:21 PM
HerbP HerbP is offline
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I bet it doesn't have the guts to do it again!!!!!!!!!!!!!!!!!!!!!!!!!
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Old 09-07-2019, 12:28 PM
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I bet it doesn't have the guts to do it again!!!!!!!!!!!!!!!!!!!!!!!!!
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Old 09-17-2019, 11:49 AM
645CiGrrr 645CiGrrr is offline
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moisture

We have sealed (and resealed) every possible area that we can think of.
The car sits inside most of the time, and the only time water seems to collect inside the headlight unit is thru a car wash. I open the hood to feel around after a wash, all is dry, so must be coming up from underneath OR somehow along the lend seal, but it was sealed with windshield/glass calk so should be ok.
I read BMW settled a suit regarding newer cars leaking into the trunk and frying the amp. I also went thru that issue, water would drain thru the back tail light right onto the amplifier POOR design.
The headlights are a similar poor design, why would the ballast be underneath the unit.
Perhaps I need to put the entire headlight unit in the bath so see if I can find the issue...very frustrating to say the least.
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Old 09-18-2019, 09:34 AM
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If you've checked all the above then maybe the seals for the module wiring is at fault on the side and bottom, maybe try putting some sealant where the modules meet the headlight body, I must say I've not heard of these being an issue but these cars are knocking on a bit now so it could be the problem .
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Old 09-18-2019, 09:36 AM
645CiGrrr 645CiGrrr is offline
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Thank you, I plan to take the bumper off when we switched to winter tires. I will look at the underside more closely.
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  #11  
Old 09-18-2019, 12:17 PM
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Just a thought but is it possible that there are two issues, with so many ballasts frying it might be a wiring problem, shorting, bad earth, corrosion somewhere in the wiring etc. or voltage regulator spiking.......my point being it might not just be a water/ condensation problem
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Old 09-18-2019, 12:24 PM
645CiGrrr 645CiGrrr is offline
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I will let the mechanic have a good look this time around you might be right.
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  #13  
Old 09-18-2019, 05:32 PM
HerbP HerbP is offline
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You could try & use a smoke tester to find your leak. It shouldn't take but a few PSI & some smoke.
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  #14  
Old 09-19-2019, 09:20 AM
645CiGrrr 645CiGrrr is offline
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Good idea, it makes me nervous to put anything in water to see if there is a leak. Thank you all for your suggestions, I should have this sorted out before the snow flies!
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