Chrushev

I have a 2003 Lancer (ES). The headlight in question is a replacement I had done when my original one got cracked on the freeway from debris around 2009. I dont know if its OEM part or not, was replaced at a auto shop (not dealer).

Visibly from the outside there are no cracks or damage.

Here is what I am planning to try.

Take out the bulb and see if O-ring on it is destroyed or not, if not then.

1) Take off the bumper
2) Take off the headlight
3) Fill headlight with water and see if I can see any leaks, then dry it out.
4) Use Caulk to patch up any leaks (any suggestions for sealant? perhaps some sort of silicone? all videos Ive seen just use house caulk like DAP). Maybe this? http://www.homedepot.com/p/GE-2-8-oz...E-57/202038072
5) Hopefully this fixes it?

Has anyone done a similar repair? Is it fairly permanent? Any recommendations on how to handle this?

If you have seen this, which part failed for you? The O-ring or joint between the clear plastic and back shell or something else?

Thanks!

Chrushev

Follow up for anyone that stumbles upon this thread.

1) In 03 model (and I imagine 01-02) bumper removal is not necessary. The headlight is held in place by 3 bolts and all 3 are accessible without removing the bumper (2 top one side towards the center of the car).
2) Instead of filling headlight with water I inspected it for cracks (there were none) and the seal between the back and front shell (clear headlight and black backing) and there were parts where insulation had gaps or has separated.
3) I dried out the inside by putting headlight in a box, cutting a hole in the box for a blow dryer to fit in and leaving it in the "hot box" for about 30 minutes, checking on it constantly to make sure nothing melts or catches fire. I used lowest blowdryer setting. (If using heatgut dont blow directly onto the headlight.
4) I used Silicone II Clear and went all around the gap covering entire gap around the headlight (http://www.homedepot.com/p/GE-Silico...-3TG/100004845).
5) Its been 24 hours and so far so good. No moisture inside.