So one of the reasons I cleared my headlights was so that I could re-seal them because they have fogged since I got the car.
Now my passenger side doesn't fog up as badly, but my grivers side is horrible!

Anyone know how to fix this without taking the whole thing apart again?

Im thinking about baking them at 200 for 20 minutes and just pushing on the lens firmly to try to get a better seal...

 

You could try that^^ and also run a bead of sealant all the way around the entire lense to seal any and all cracks. Have you tried the hair dryer method?

 

Nissan Butyl Rubber Sealant. Seach that for a part number. You can buy at the Nissan dealer parts desk.

Also dessicant packs. Either replace the OE ones or get new ones.

 

I did the Butyl rubber and I had fogging after the first drive after reassembly (passenger side). I assumed that was just residual moisture from having them open. Then, about six months later, I saw a little fog in the driver's side. Odd because it was really windy that day so I had dust all over the car. I decided to wash it before tucking her away for the weekend. So I washed the car in the wind storm and while drying, I noticed fog in the driver's side. Could the wind have pushed moisture in where rain and car washing normally wouldn't?

I've done like 4 other sets of headlights where I only used the stock sealant and didn't add any. The TL is the first set that I added it and it fogged up. Odd.

 

No i havnt tried the hairdryer method. what is that?
And the tl must have a design flaw because mine fogged up when they were bone stock.

 

Dont forget to use the silica packets JnC recommends as a major cause of fogging headlights...

Thread from JnC-----> https://acurazine.com/forums/2g-tl-problems-fixes-117/clearing-headlights-long-write-up-592215/

 

Here you go sir,
I had a little theory about the humidity inside the headlight...it's not from rain/penetration...it's from humidity trapped inside from opening then sealing and closing up the light.

Trust me, I thought it up...and after 3 pairs of fog free lights in South Florida with humidity and rain...I am CERTAIN I am right.

Here, this is the DIY thread I made for blackout...in the first post I give a little blurb on the hairdryer method. Can be done on the car.
BEST way IMO...wait till you have the condensation on the inside of the lense, then do the blowdryer thru the garden hose with another light socket open to let the hot air out...you'll actually watch the condensation turn to vapor and disappear. Then seal back up...
Takes about 10 minutes per side.

 

J where's the link?

 

whoops...ADD kicked in...sorry,
https://acurazine.com/forums/3g-tl-2004-2008-93/those-about-rock-no-wait-i-meant-blackout-headlights-new-idea-774441/

 

and by "seal back up" I meant put the bulbs back in...also add some regular teflon tape to the bases of the bulbs...mainly the DRL/fog light bulb.