Novak Conversions Jeep Wrangler JK engine mounts

Headlight bubbled

IH8MUD

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Dec 30, 2022
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I own. 2105 JK unlimited and just noticed that both headlights seem to have melted (only at the 12 o’clock position). Just got it back from the dealership and noticed this! Any clue what caused this? We had a recent cold snap in Tampa however I’ve never seen this before.

91D8D486-BA40-4C55-93A9-C446C44D7CB0.jpeg
 
Moisture in the headlight. JK headlights are not sealed, the bulb is separate to the lens. So humidity and temperature changes can cause this. The trip to the dealership had nothing to do with it.

If it really bothers you, you can remove the bulb and swab it out. You can fasten a dry cloth to a stick.

Or you can replace them with LED headlights that are sealed. The JK headlights are notoriously terrible anyway.
 
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We had a recent cold snap in Tampa however I’ve never seen this before.
Those of us who live in climates other than year-round spring and summer are familiar with the concept of condensation. (sarcasm employed at will)

As soon as the temp and humidity level inside the lens matches the outside temp and humidity it'll disappear.
 
Those of us who live in climates other than year-round spring and summer are familiar with the concept of condensation. (sarcasm employed at will)

As soon as the temp and humidity level inside the lens matches the outside temp and humidity it'll disappear.
The lens is warped. It actually melted.
 
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Moisture in the headlight. JK headlights are not sealed, the bulb is separate to the lens. So humidity and temperature changes can cause this. The trip to the dealership had nothing to do with it.

If it really bothers you, you can remove the bulb and swab it out. You can fasten a dry cloth to a stick.

Or you can replace them with LED headlights that are sealed. The JK headlights are notoriously terrible anyway.
Would the extreme heat melt the lens? Because the lens is actually warped.
 
I was agreeing with the brothers on this one.
Condensation . But your saying it burned
and melted the lense?
Not a clue what would cause that.
Halogen bulbs do run pretty warm but enough
to melt the lense? Maybe if it was someohow
shorted ? IDK
Look at it this way. Gives you a chance to upgrade
to LED's. But I would search things out and fig
what caused this anomally.
 
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The lens is warped. It actually melted.
Okay, then. Sorry, I thought it was just a condensation/moisture issue.
Nonetheless, it should not have happened. Can you see a noticeable difference in the brightness of tht headlight over the other? Perhaps a previous owner put a different, brighter, hotter burning bulb in the headlights?
Anyway, as previously mentioned, this gives you an opportunity to install a decent quality, sealed LED bulb that is far and away much better than the OEM headlights.
 
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If it got hot enough to melt the lens, I'm amazed it's still working. The wiring should have melted, and it's frankly surprising that you're not telling us about the time your Jeep burned to the ground...

Regardless, I'd swap them for LED lights (not bulbs) and be done with it.
 
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Aftermarket lamps that run way too hot for the housing will do this.
Those lamps were probably replaced w/ 100W at some point, which is better to see with for sure, but they create a lot more heat.
 
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I appreciate everyone’s replies! I’m the original owner of the Jeep, special ordered a Hard Rock. These are the original bulbs and headlight lenses. I haven’t added any aftermarket items other than a warn winch about 2 years ago. I’m still perplexed. I bought the lifetime warranty and have an appointment on the 14th of January. I have 116,000 miles and it’s a 2015 unlimited. Lights still shine bright. I recently had an engine light come on with an indicator on my Trip telling me it’s my gas cap. Replaced that with an OEM cap but the code won’t go away. Dealership said they would have to do a deep diagnosis…don’t understand this. Thanks everyone, I appreciate the input
 
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I appreciate everyone’s replies! I’m the original owner of the Jeep, special ordered a Hard Rock. These are the original bulbs and headlight lenses. I haven’t added any aftermarket items other than a warn winch about 2 years ago. I’m still perplexed. I bought the lifetime warranty and have an appointment on the 14th of January. I have 116,000 miles and it’s a 2015 unlimited. Lights still shine bright. I recently had an engine light come on with an indicator on my Trip telling me it’s my gas cap. Replaced that with an OEM cap but the code won’t go away. Dealership said they would have to do a deep diagnosis…don’t understand this. Thanks everyone, I appreciate the input
Jeep Dealer Deep Diagnosis
" plug in OBD2 and
hope it tells them somethimg"

If you ever fig out what caused extreme
heat to melt lenses. Please let us know
for future reference . THX
 
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I appreciate everyone’s replies! I’m the original owner of the Jeep, special ordered a Hard Rock. These are the original bulbs and headlight lenses. I haven’t added any aftermarket items other than a warn winch about 2 years ago. I’m still perplexed. I bought the lifetime warranty and have an appointment on the 14th of January. I have 116,000 miles and it’s a 2015 unlimited. Lights still shine bright. I recently had an engine light come on with an indicator on my Trip telling me it’s my gas cap. Replaced that with an OEM cap but the code won’t go away. Dealership said they would have to do a deep diagnosis…don’t understand this. Thanks everyone, I appreciate the input
Evap purge leak is nearly always the cause. There's a purge valve under the hood, a couple hoses between that valve and the fuel tank, with a cannister in the middle. They crack and leak all the time. Easy repair.
 
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I appreciate everyone’s replies! I’m the original owner of the Jeep, special ordered a Hard Rock. These are the original bulbs and headlight lenses. I haven’t added any aftermarket items other than a warn winch about 2 years ago. I’m still perplexed. I bought the lifetime warranty and have an appointment on the 14th of January. I have 116,000 miles and it’s a 2015 unlimited. Lights still shine bright. I recently had an engine light come on with an indicator on my Trip telling me it’s my gas cap. Replaced that with an OEM cap but the code won’t go away. Dealership said they would have to do a deep diagnosis…don’t understand this. Thanks everyone, I appreciate the input

Just stumbled onto this thread after a quick search. I know this thread is a couple years old but hoping you can shed some light on what you found out.

My 2015 JK 136,000 miles - original owner, original headlights - did the exact same thing and I noticed the bulbs were melted in the exact same pattern as yours AFTER picking it up from the dealership. Also had taken it in for an evap code, engine light and gas cap message.

Hopefully someone can shed some light on this? These can't be the only two JK's with this issue. I have no idea how the dealership could have done this, but it is awfully coincidental...

Side note; dealership said a valve was sticking and my left head needed replacement as well as some evap sensors and gasket. $7,800. So now it is sitting in my driveway while I contemplate next moves.
 
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Just stumbled onto this thread after a quick search. I know this thread is a couple years old but hoping you can shed some light on what you found out.

My 2015 JK 136,000 miles - original owner, original headlights - did the exact same thing and I noticed the bulbs were melted in the exact same pattern as yours AFTER picking it up from the dealership. Also had taken it in for an evap code, engine light and gas cap message.

Hopefully someone can shed some light on this? These can't be the only two JK's with this issue. I have no idea how the dealership could have done this, but it is awfully coincidental...

Side note; dealership said a valve was sticking and my left head needed replacement as well as some evap sensors and gasket. $7,800. So now it is sitting in my driveway while I contemplate next moves.

I had a headlight bulb do this years ago in my Ford Explorer. The bulb somehow malfunctioned and had both high and low beam on at the same time. It started to get so hot that it melted the headlight housing, the bulb body, the socket where the bulb connected to the housing and my OEM wire harness connector. Never blew a fuse though.
 
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Novak Conversions Jeep Wrangler JK engine mounts