1. Attachments are working again! Check out this thread for more details and to report any other bugs.

Moisture inside LED headlams =$$$!

Discussion in 'Gen 3 Prius Care, Maintenance & Troubleshooting' started by homegameroom, Jan 7, 2012.

  1. homegameroom

    homegameroom New Member

    Joined:
    Jan 2, 2011
    37
    8
    0
    Location:
    Cleveland, OH
    Vehicle:
    2010 Prius
    Model:
    V
    I noticed some moisture inside my LED headlamps (more than just a little condensation) after washing the car a month or so ago. There was an UNUSUAL amount of moisture, but I figured it would go away eventually. It sort of did... not.

    The next thing I know, I'm getting this in the display (Picture 1):

    The warning would always show in the display and the yellow Triangle Of Death was also blinking. So I pulled the headlight out (yes, the front fascia needs to come off almost completely) and dried the headlamp assembly and the computer out. Still no luck. (Picture 2)

    So I called the dealer and junkyards. I know about the leveling motor and the control assembly (like a little computer) attached to it, so I went with the junkyard. Strangely, it came in this box: (Picture 3)

    It did come with the leveling motor (as it would have from the dealer), but was missing the computer. Rats! So I bought another computer for it and attached it to the headlamp with the included gasket. (Picture 4)

    Now, everything is installed and works as it should. Bottom line: If you have the LED headlamps and see ANYTHING OTHER THAN CASUAL CONDENSATION IN THERE, CLEAN IT UP QUICKLY before further damage occurs!!

    I did not want to put the new computer on the old headlight or vice-versa in case one damaged component would kill the other good component. Yes, I'm out of warranty and my dealer didn't even pretend to want to help me out. In spite of this, I do like the LED headlamps - I'll just be quicker to respond if there's a seal failure in the headlamp housing!
     

    Attached Files:

    #1 homegameroom, Jan 7, 2012
    peterjmc likes this.
  2. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

    Joined:
    Feb 14, 2010
    6,035
    3,855
    0
    Location:
    Rocky Mountains
    Vehicle:
    2006 Prius
    Model:
    Three
    The headlamps are not sealed, and most are not and have not been since the 80's. As long as there is air, it will get inside. And when air sees a temperature difference (hot lamp, cool outside) condensation forms. So it needs a way in and out, so no seal.

    When you wash the car, generally not much gets in there as it is designed that way. But if you go really slowly over the "undercarriage wash" that alot of places have, this is a bad idea. Water on the roads does not shoot upwards into the engine, and gravity makes water go down, making it an ideal spot to put drains.

    What kind of car wash did you do?

    Glad you got it fixed at a reasonable expense.
     
    #2 2k1Toaster, Jan 7, 2012
  3. homegameroom

    homegameroom New Member

    Joined:
    Jan 2, 2011
    37
    8
    0
    Location:
    Cleveland, OH
    Vehicle:
    2010 Prius
    Model:
    V
    There are a few little vents on the headlight assembly, but, upon further examination, I think the water came in by the high beam. There's a rubber diaphragm by the light socket (Pic 2) (so the high beam can move and align with the low beams) and the bottom of it wasn't on very well. Be careful when washing under the hood! :mad:

    So, time for Fun With A Sawzall!!!

    I took the leadlight apart to see what makes it tick. There were 2 swivel mounts at the top of the unit; the alignment motor (see Pic 1) makes the third contact point for mounting.

    Pic 3 shows the back of the unit; Pic 4 shows the front with the high beam reflector removed. Pic 5 shows the front of the unit with most of the refelctors removed; Pic 6 is a closeup of one of the LEDs.

    I imagined there was more than 1 LED per reflector. There isn't. I was also surprised there were only 2 wires going to each LED.
     

    Attached Files:

    #3 homegameroom, Jan 7, 2012
  4. 32kcolors

    32kcolors Senior Member

    Joined:
    Jul 14, 2009
    5,683
    953
    124
    Location:
    Redondo Beach, CA
    Vehicle:
    2010 Prius
    Model:
    V
    I had my passenger side LED headlight replaced under warranty at 25K miles for the same problem due to split seal and yes, they're expensive at $800 a pop.

    Condensation is normal but actual water droplets aren't and won't go away (they may dry up in the sun but will eventually return at nights).
     
    #4 32kcolors, Jan 7, 2012
  5. rrg

    rrg Active Member

    Joined:
    May 18, 2010
    458
    120
    41
    Location:
    East coast - NJ
    Vehicle:
    2011 Prius
    Model:
    Two
    I had the same condensation on day 1.
    But the dealer said it's normal per the manual.
    Yes the book does say normal.
     
    #5 rrg, Jan 7, 2012
  6. 32kcolors

    32kcolors Senior Member

    Joined:
    Jul 14, 2009
    5,683
    953
    124
    Location:
    Redondo Beach, CA
    Vehicle:
    2010 Prius
    Model:
    V
    Temporary condensation build-up is normal. The manual specifically says to contact your Toyota dealer for more information in the following situations:

    - Large drops of water are built up on the inside of the lens
    - Water has built up inside the headlight

    They can tell you whether or not there's an actual leak, but generally if the problem is persistent or affects only one side but not the other it's strongly indicative of a split seal like in my case.
     
    #6 32kcolors, Jan 8, 2012
  7. homegameroom

    homegameroom New Member

    Joined:
    Jan 2, 2011
    37
    8
    0
    Location:
    Cleveland, OH
    Vehicle:
    2010 Prius
    Model:
    V
    Yep, I had drops - many of them! Enough that the module at the bottom was pretty wet.
     
    #7 homegameroom, Jan 8, 2012
  8. wogue

    wogue Lexus CT200h

    Joined:
    Jun 13, 2007
    61
    2
    0
    Location:
    EU/Austria
    Vehicle:
    Other Hybrid
    Model:
    N/A
    It's not the same issiue here, but in the german forum some detected this issue with the LED headlight:

    Prius III Executive LED Scheinwerfer - PRIUSforum

    There seems to be some kind of oxidation behind the lenses. It's the metal part that produces the sharp edge between light and shadow.

    To avoid eye damage: Implicitly switch off the LED headlamps while you examine this!!! Never look directly into a LED beam source!!! Use a torch instead!!!
     
    #8 wogue, Jun 24, 2012
  9. NiHaoMike

    NiHaoMike Member

    Joined:
    May 6, 2012
    98
    16
    0
    Location:
    San Diego, CA
    Vehicle:
    2011 Prius
    Model:
    Four
    If the LED still works, maybe wire a power adapter to it to use it as a desk lamp?
     
    #9 NiHaoMike, Jun 24, 2012
(You must log in or sign up to post here.)