Below is a photo of the kit that Chrysler sold to rid the headlights of the condensation problem. It shows the parts for one headlight, the new cover and the two caps that completely covered the holes where the 'T' shaped breathers fitted originally. There was two of these kits required, I am not sure if they came in a single kit or if two kits were required. I never really had the problem but I fitted the kit anyway. You can see the rectangular insert that prevents the ingress of water and provides an outlet for water vapour.


I have an idea that a square could be cut in two of the covers, one for both sides, and a piece of Gore-Tex or a similar material glued over these holes with the rainproof side on the outside and the breathable surface inside. Or is there some other material that would be better?
The two 'T' shaped fittings being replaced with rubber plugs like those shown in the kit above.
The idea being that water would not get through the Gore-Tex and water vapour could escape through from the inside. Obviously the air inside the headlight unit would expand when heated by the bulbs driving air out, my question on this is would the air escape fast enough to avoid blowing the cover of and let air pass back into the headlight when it cools down.
Some headlights in the past have had leaks in the sealant allowing water to get into the headlight, I saw one headlight at the Dragon in 2010 with enough water in it to keep a goldfish alive, it must have had a bad leak somewhere.