MuRaN0Daddy

<center><img src="http://pictureposter.audiworld.com/35713/img_2848.jpg"></center><p>
Thanks to diagnosticator for doing just that. Fogging or not, this may be a worthwhile project. The OEM "O" ring is clearly not right. There was H2O getting into the housing at this point.
1. remove your housings.

<img src="http://pictureposter.audiworld.com/35713/img_2849.jpg">

<img src="http://pictureposter.audiworld.com/35713/img_2850.jpg">
this is the outside adjuster cover.

<img src="http://pictureposter.audiworld.com/35713/img_2851.jpg">
This is with the cover removed, the gear thing on the bottom right is what you will pull straight out. You can use needle nose if it's sticky.

<img src="http://pictureposter.audiworld.com/35713/img_2853.jpg">
see the O ring? see how "sunken" into the channel it is?

<img src="http://pictureposter.audiworld.com/35713/img_2854.jpg">
Old ring, new ring, graphite.

<img src="http://pictureposter.audiworld.com/35713/img_2855.jpg">
old ring off, new ring on.

<img src="http://pictureposter.audiworld.com/35713/img_2857.jpg">
comparison.

<img src="http://pictureposter.audiworld.com/35713/img_2858.jpg">

Home Depot $1.27
<img src="http://pictureposter.audiworld.com/35713/img_2859.jpg">
OK. the OD and section of the new "O" ring is too fat. But this is the ring you need. When in place, it will not allow the gear shaft to fit back in the housing and sit flush to allow the cover to be put back on. So, you must deepen/widen the groove that the ring sits in. you can file it. I used a Dremel, carefully. go slowly, file some away, use the graphite to lubricate the ID of the O ring, put the ring on, try it. If it drops in, you should feel a little resistance as is will fit snug, but flush. If it does'nt drop in, file away a little more, and so on til' it fits back in snugly.
I hope this helps someone, me included.
Peace.
DD.
Senator, the floor is now open for questions.

Audi RSF1

There's always something else : )

2touchA4 - SOLD

you and your dremel

MuRaN0Daddy

"Just when I think I'm out; they pull me back in." MC.
Wait til I get an A3 :-)

diagnosticator1

Although this mod is very simple in concept, there are always numerous little details involved with the execution. It's hard to address all of the things to consider concerning the topic when posting. The question is how to limit the scope of the post while still providing enough information to be usable.

EGainer

but what about cleaning the inside of the housing

MuRaN0Daddy

I made many assumptions. Like removing your headlight housings. Although I realize possibly hundreds of readers may have never removed their housings, if you are considering doing this fix, most likely, you have. If you haven't, and need help, search, or post a Q.
The 30 Torx may or not be a given, again, needed to remove the cover. Then of course, the never ending Q "will this void my warranty". If you are asking that question, then indeed this type of DIY may not be for you.
But, I will remind you n00bs, in 02', when I bought my 1st Audi B6, I couldn't spell headlight, let alone do some of the things to them that I have! LED's, E Codes, this fix, xenon in, xenon out, etc!
You bought it. It's yours, take ownership! Everyone on this board will help you! Including Scott. j/k.
DD.

MuRaN0Daddy

that's the real deal getting that sealed unit apart. Not fot the weak of heart. If you mean the fogging, it left no residue on my lens on either side.

EGainer

shouldn't be attempting projects that involve things like this

diagnosticator1

using some Dawn dish soap, then immediatley rinsing with distilled water, followed by some denatured alcohol after that.