Despite having dryed it out twice the drivers side headlight shows significant condensation inside the lens as soon as I go through a car wash or any amount of rain. The dealer thinks that the seal on the lens has failed and my Ensurall warranty will not pay to repair it (not mechanical breakdown). Not a big problem in itself but I worry about corrosion of the enclosed electrics. Replacment lens is over $1000 Cdn. Has anyone had this problem and tried to reseal the join?

 

I seem to remember reading something about installing a vent kit from Porsche. I just found it. Go to renntech.org. pay the donation fee, and look at TSB's the vent kit is a TSB.

 

Try removing it from the car. Remove the back covers. Take air compressor nozzle on low pressure and blow into the unit feeling with your other hand any places along the edge where air escapes. Apply some liquid gasket using masking tape and you have sealed the fault. At least I did this on a minor hair line crack on my VW's tail lamp assembly.

 

What year Cayenne?

How much condensation? Fog or water drops?

There is a $30 replaceable gasket that surrounds Cayenne headlights that usually solves the problem:

 

Thanks for the suggestion. Its a 2006, and it's water droplets not fog. I'll take a look a look at the gasket but the enclosure is sealed just fine on the back with all the rubber caps properly in place.

 

Gasket is on the surround of the headlight (clear plastic part.) Also note that on the underside of the headlight is a round plastic disk with a filter...this should be clean and unobstructed.