Headlamp "clearcoat" failure

[Donny Carlson]

My right headlamp assembly is being replaced under warrantee. I have just reached 29K miles.

Around 20K I noticed my right headlamp had what appeard to be fogging on the lense. There was no accumulation of moisture that I could see, so I figured that I was SOL for the TSB and getting the lamp replaced under warrantee. But the patch has grown, and the entire lense now has a white cast to it. It's obvious that before long the lense will be completely white, like you see on older Mustangs and Cougars or Tbirds.

Steve Babcock noticed this on my car at MVII, tells me that this is a defective headlamp and suggests I get it replaced under warrantee. What I learned from Silver '04 was these assemblies are clear coated, and my clear coat was coming off, or not applied correctly, or some other failure.

Today, after several photos were transmitted over the net to Ford with the lights on and off, at different angles, they approved replacing the lamp.

[mtnh]

Donny, what are you using for bulbs in your headlamp assemblies? I'm wondering if it is due to gassing of the aftermarket bulb's coatings. I am running silverstars and seem to notice a clouded area right in the middle of the lenses.

Thanks,

Mike

[TAF]

Donny, what are you using for bulbs in your headlamp assemblies? I'm wondering if it is due to gassing of the aftermarket bulb's coatings. I am running silverstars and seem to notice a clouded area right in the middle of the lenses.

Thanks,

Mike
It has nothing to do with the SilverStars that Donny has, this is a known problem (headlamp fogging) that plagued many of the first year models. The TSB calls for headlamp replacement with a completely new headlamp assembly that has a different part number.

[rayaa]

my black 03 MM had the same problem- had them replaced under warranty. Here in FL the humidity is obviously high, may have contributed - there was condensation present.

[Donny Carlson]

Donny, what are you using for bulbs in your headlamp assemblies? I'm wondering if it is due to gassing of the aftermarket bulb's coatings. I am running silverstars and seem to notice a clouded area right in the middle of the lenses.

Thanks,

Mike
I don't think what is happening to my headlamp is condensation (sorry Toddmeister). The plastic is turning from clear to white, and a large, irregular patch in the center is much whiter than the rest of the plastic. If you look at the two assemblies on my car, the driver side light is crystal clear, the passenger side is noticabley white - the entire lense is white - with this nasty white crud in the middle.

Chris told me this was defective clear coat on the lense. Whatever the issue, I'm getting the assembly replaced.

The actual lamps (which are Silverstars) play no issue here.

[Silver_04]

I used to work for a company that made Grand Marquis headlamps and when they started turning white or yellow on the outside it was because the clear coat paint applied to the lens had failed. This is just what exposed polycarb plastic does over time. It isn't a surprise that a lens would leave the factory without paint because it is very difficult to detect colorless paint on a colorless part. I tried to patent a process to detect the paint but I don't know what happened to that since it's been years since I worked there. Oh well.

Donny it almost seems as if your lens has way thin paint on it or no paint at all. Yours definately sounds to be a case of decaying exposed polycarb. plastic.

[Svashtar]

Just had my 3 week old car right front headlamp replaced because of this. Looked like a peeling patch right off the middle of the light. The dealer replaced with no question with a new unit.

Norm

[mtnh]

Okay, final question: Is the clear coat on the inside or on the outside of the headlight assembly?

Thanks,

Mike

[Svashtar]

Okay, final question: Is the clear coat on the inside or on the outside of the headlight assembly?

Thanks,

MikeThe outside for sure. Trying to rub it out will only make the damaged spot larger.

Norm

[drobin]

There is a kit available with all the necessary items to completely re-condition and re-seal all clear coated lenses that are fogging up. I tired one on my Grand Marquis and it came out like new. Marauder is garage kept and lens are clear but who knows what will happen in time to come...

drobin
"Donald"

[sailsmen]

My left lense is doing the same thing, clear coat foging up but on the inside, it's not form condensation.

What is the TSB number?

[jgc61sr2002]

If I am reading it correctly TSB # 201200 Electrical Exterior Lighting or #16997.

[studio460]

There is a kit available with all the necessary items to completely re-condition and re-seal all clear coated lenses that are fogging up.Sounds very interesting--would like to hear more about specific products . . . I've actually been meaning to apply either a clear 3M protective film or an actual window tint film (of a very high transmission) to the headlamp covers myself. Since the headlamp cover front is fairly planar in shape, I thought this might be an easy, doable mod. A very light tint film I think would really add to both the car's cosmetics as well as act as an excellent protective film. Yeah, yeah, yeah . . . I know that you're not supposed to tint headlamps!

[drobin]

Sounds very interesting--would like to hear more about specific products . . . I've actually been meaning to apply either a clear 3M protective film or an actual window tint film (of a very high transmission) to the headlamp covers myself. Since the headlamp cover front is fairly planar in shape, I thought this might be an easy, doable mod. A very light tint film I think would really add to both the car's cosmetics as well as act as an excellent protective film. Yeah, yeah, yeah . . . I know that you're not supposed to tint headlamps!

Shooter, call Bright Solutions Inc. at 800-604-6377 for the Plastic and Headlight Resurfacer/Protector Kit. My composite headlight assemblies on my Mercury Grand Marquis looks brand new..Cost of kit around $29.00

Let me know how things turn out for you !!!

drobin
"Donald"

[Donny Carlson]

Shooter, call Bright Solutions Inc. at 800-604-6377 for the Plastic and Headlight Resurfacer/Protector Kit. My composite headlight assemblies on my Mercury Grand Marquis looks brand new..Cost of kit around $29.00

Let me know how things turn out for you !!!

drobin
"Donald"I've seen this -- or a similar kit -- advertised in MMFF (I think)

Anyway, shooter, look here:

http://detailking.goemerchant7.com/index.cgi?PageToView=catalog&Department=160854&Cartid=24921076080575&Merchant=detailking&ExpandedDepts=

and here

http://www.mdwholesale.com/

[Marauder2005]

Dont have my Marauder yet but my crown vic had this problem. When I got new headlights the detailer at the body shop recomended that I use cleaner wax on them every time I wax my car. The lenses are clear as a bell and show know signs of fogging.

[valleyman]

Dont have my Marauder yet but my crown vic had this problem. When I got new headlights the detailer at the body shop recomended that I use cleaner wax on them every time I wax my car. The lenses are clear as a bell and show know signs of fogging.

What's "cleaner wax?"

[Dr Caleb]

What's "cleaner wax?"

It's usually the first step in a 3 step system wax. It has mild abrasives to remove oxidized paint.

Maguires #2 or #9 are examples. I use a mild abrasive on my CV headlamps (glass, not plastic) all the time - it cleans them right up.