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      01-15-2026, 10:13 PM   #3891
ctcarbonari
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Drives: 2015 BMW 535i M Sport
Join Date: Feb 2022
Location: Vancouver, WA

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2015 BMW 535i  [0.00]
Quote:
Originally Posted by s_ribs View Post
What thickness weather stripping did you use? I grabbed some off amazon that is 1/4" thick and there was no way I was getting the caps back on. Wondering if I need to find something that's 1/8" thick instead.
1/4" window weather stripping from Lowes. And yes, I had to mash the cap back down and twist.

Long story short: My condensation issues came back after 2-3 weeks. Twice I removed the headlamp assembly entirely, dried completely, and went at every possible mating point I could find with silicone. Both times it seemed to work after reassembly; however, again, after 2-3 weeks the condensation would return and gradually get worse.

Last week I installed a new headlight assembly. Condensation issue fixed. However, I have to go back at it one more time and install a new Xenon Headlight Control module as I let the issue persist for too long and fried the board. (Low Beams, High Beams, turn signals work. Adaptive lighting and DRLs do not)

Don't do what I did and wait too long, that board sits at the bottom of the headlight assembly and is very susceptible to the moisture.
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