Well I figured it out and fixed the problem, and it wasn't the housings but I still replaced them both under warranty anyway, took some convincing to my service manager to do it but I won in the end lol. I actually ended up doing two "repairs" to the bulbs.
I did not buy extremely expensive HID replacement bulbs, the bulbs them selves were $40 for the pair off of highperformancebulbs.com. I took the truck to one of those no touch car washes and bought the most expensive wash since that would spray the most water for the longest time. Then I took it directly to where I work and put it up on the hoist to blow compressed air at the fog light to see where the water was coming in from.
The actual lenses are sealed perfect, none of the water moved when i blew air around the lens to housing seam. Then I blew air around the bulb and BOOM water was moving inside the lens all over the place.
I found two problems:
1. The HID bulb was slightly loose even in the locked position, I could pull it back and forth about a milimeter.
2. The bulb was not sealed where the wires go into the bulb, water was actually coming through the bulb via the wires.
I fixed problem one by taking the o-ring off the stock h10 bulbs and putting it below the HID o-ring on the base of the HID bulb. Basically it takes up that 1 mm gap and makes the bulbs nice and tight in the housing, like the stock bulbs.
As for problem two I put a small dab of silicone where the wires go into the HID bulb, after the silicone dried I wrapped the wires in electrical tape making a "loom" like all the factory wiring on the truck. Water can't get anywhere close to the wiring or the bulbs.
I blew out the housings and let the completely dry (luckily no staining or discoloring happened to my brand new housings) and drove the truck around for 3 days just to make sure they where completely dried. Last night I took it through the same wash at the same car wash as before and there wasn't a drop of water in either housing, no water, no moisture, no fog, nothing. I did buy a set of 6000k HID bulbs from retrosolutions.com because I planned on just changing out the bulbs AGAIN, but now that this works I'm just going to store those untill I need them because these cheaper bulbs actually do look really good and match my headlights perfectly.
Also looking at the retro solutions bulbs, they are sealed where the wires go into the bulbs, so If anyone else ever has a problem with water in their fogs with HID's you can either do what I did, or buy your bulbs from retro solutions.
Sorry for the novel...
Chrysler Dealership Engine, Trans, Axle "Heavy" Tech of 3 years
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Last edited by frickenbored; 02-02-2013 at 02:24 PM.