Originally Posted by BFlinn181
Sounds like a leaking gasket, that's a lot of water to be just condensation. If you drill one small hole at the low point, that would be enough to drain any future condensation or a leaking gasket.
Yeah, I was hoping for a leaky gasket, but the thing is just one solid chance of plastic,..errr..poly something or other. Unfortunately the wiring for the headlight itself was routed in such a way that I couldn't take the unit into my shop, but i was able to drill two 1/4 in. holes, one below the headlight, and one below the running light. I drained all of the water out of the assembly as best I could, Installed new bulbs, and reinstalled the thing into the RV. Everything worked. Then I used 3M headlight polish to clean up the outside of the assembly , and Aerospace 707 to make the plastic happy.
Thanks to the responders for their ideas!