Bamainkdgrl Posted November 30, 2020 Share Posted November 30, 2020 So I installed H11 led headlight bulbs and with the fan being part of the light unit my dust caps won’t fit back over. Leaving them off is causing condensation to build up inside the headlight assembly and drives me crazy. Anyone figure out a way to make them work? I suppose I could cut around the fan but getting a good seal would be difficult. 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted November 30, 2020 Share Posted November 30, 2020 10 hours ago, Bamainkdgrl said: So I installed H11 led headlight bulbs and with the fan being part of the light unit my dust caps won’t fit back over. Leaving them off is causing condensation to build up inside the headlight assembly and drives me crazy. Anyone figure out a way to make them work? I suppose I could cut around the fan but getting a good seal would be difficult. Hi Bamainkdgrl. You do not mention the model year/trim level of your Fusion. However...Unfortunately, the headlight housings of your Fusion are not designed for LED bulbs, and LED bulbs should not be used in them for a multitude of reasons. What are few (but not even all) of the reasons? - First...because they do not fit properly, as you now know. - Second...because the light pattern will not be cast properly and you will most likely cause dangerous glare for oncoming drivers. - Third...because they are illegal in the U.S. and Canada. It is illegal to use a non-approved bulb in a headlight housing not designed for that type of bulb. Your headlight housings were designed for Halogen or HID bulbs (we can not determine which). That is why the fine print for all these aftermarket bulbs states "For off-road use only" or something similar. Will you be pulled over and ticketed? Probably not. But they are still illegal and cause problems for the vehicle owner and more importantly, oncoming drivers. Good luck with whatever you decide to do. 0 Quote Link to comment Share on other sites More sharing options...
Bamainkdgrl Posted December 6, 2020 Author Share Posted December 6, 2020 Sorry, first time posting of course I’d forget the details. My Fusion is a 2011 SE. The LED bulbs I installed say “focused beam technology, won’t blind oncoming vehicles”. As far as the housing, the LEDS are just a bit longer than the halogen bulbs, being they have the cooling fan. But it’s just enough that the caps won’t stay. I’ve considered cutting an X into the cap where the fan part is and then a small circle to ensure a sealed fit, or atleast a better seal than what it is currently. But was curious if anyone had other thoughts on this. The condensation inside the housing of my brand new headlights is not ideal. 0 Quote Link to comment Share on other sites More sharing options...
bbf2530 Posted December 6, 2020 Share Posted December 6, 2020 1 hour ago, Bamainkdgrl said: Sorry, first time posting of course I’d forget the details. My Fusion is a 2011 SE. The LED bulbs I installed say “focused beam technology, won’t blind oncoming vehicles”. As far as the housing, the LEDS are just a bit longer than the halogen bulbs, being they have the cooling fan. But it’s just enough that the caps won’t stay. I’ve considered cutting an X into the cap where the fan part is and then a small circle to ensure a sealed fit, or atleast a better seal than what it is currently. But was curious if anyone had other thoughts on this. The condensation inside the housing of my brand new headlights is not ideal. HI Bamaainkdgirl. I understand that the packaging says "“focused beam technology, won’t blind oncoming vehicles”. However, that is marketing BS and means nothing. I can legally and semantically pick that marketing statement apart on at least two levels, but it does not matter. They will cause glare for oncoming drivers and are illegal for on-road use, because your headlight housings and reflectors were not designed for LED bulbs. That is both legally and factually undeniable. Okay, now that being said, on to your condensation problem: Even a pinhole can result in condensation. As long as the headlamp bulb is not properly sealed to the housing, you will have a condensation problem. Cutting and X and then trying to trim the cap to fit will not eliminate the condensation problem. It will not be a tight fit and the condensation will continue to be a problem. People have tried it. There will will be an improper seal and you will still get condensation. Good luck with whatever you decide to do. 0 Quote Link to comment Share on other sites More sharing options...
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