I recently discovered that water was leaking into my SCrew and I'm stumped where it is getting in.

Some may remember that I did the door seal mod last weekend and I thought this was the cause. The silicone tube was still tight and was pulling the seal down at the corner. I massaged the seal (to allow the tube to relax) and re-seated it in the door. However, I've noticed that water is still getting in.

A rain storm filled the channel under the door trim within 3 hours. I didn't think to take a photo before I started sopping it up.




I noticed the first visible sign of water was here at the seam between the dash and the trim near the glove box.



I'm left with the impression the water is flowing in under the trim around the window until it gets to that point.

Do I need to pull apart the trim around the door? Do you think it is still coming from the mod (the silicone tube is not fully relaxed in the seal) the thing is there is no sign of the leak from the back doors or the driver side front door.

 

If this just started after the first rain since doing your door seal mod, I'd suspect that's the culprit. But ironic timing of other issues is always possible.

The water droplets by your glove box, is that how you found it or a result from cleaning it up?

I'd put down some towels, sit inside the truck, and have someone hold a hose over the door and windshield. Maybe you can see where it's coming in.

I'm still learning my way around these trucks, but are there drain tubes near the base of the windshield? I know a few cars have these by the base of the windshield. Overtime, these can get clogged with debris and allow a heavy rain to overflow the area, then start leaking in from behind the dash.

 

I have had this exact same thing happen to me. I'd love to know what causes it too

 

I don't know what your silicone tube does or looks like. But I had a major leak because the door seal was not set correctly after headliner job. If you suspect door seal, what you can do is to put a piece of paper (about an inch wide) on the door seal and close the door. If you can pull the paper out without resistance, the seal is not rain tight. I did it all around the door seal.

 

The silicone tube did pull the corners down and I had to manipulate the tube to get it closer to the original shape. I'll continue to adjust it to get it to sit properly.

Thanks all for your comments. I've decided to pull out all the trim (maybe even the roof liner if I find signs of water damage) and carpet and padding. This will serve two purposes: 1. allow me to look for more signs of water infiltration; 2. dry out the wet carpet and padding (I don't want to grow mold).

It is quite possible the carpet padding was so full of water that once I fixed the leak, it took time for the water to drain from the mat by gravity. If no other signs of leaking occurs, I'll probably start my sound-deadening project early.

 

When I got it, my Expedition leaked like that on the passenger side. It was coming from the windshield. There was a little pinhole on the top of the passenger side pillar that it was coming through. Ironically, after I had the windshield replaced, it began to leak on the drivers side... but that as since been resolved.

I know from experience that you will want to get that resolved, ASAP. That carpet will get stinky and mildew on you.

 

I've pulled the seats carpet and trim and as I suspected the pad near the leak was saturated, no additional water was found and no additional leak.

I was pleased to see that Ford did have some dampening to the floor, but there is room for improvement.

 

So it appears that my Screw imagines itself as a blooming magician. With a sleight of hands and unusually uncanny timing it plugs up the drains for the moon-roof right after I spend a lot of time messing around with the weather seal around the door. Even more curious, it chooses the one side of the truck where the weather seal is most poorly seated.

I found the leak today because with all the insides outside, I was able to follow the path of the water by pulling out the rest of the trim and following it up to the roof line; where I noticed the beginnings of water stains around the opening of the moon-roof.

Tomorrow, figure out how to un-plug those drain tubes. Also, test out an idea I have about making the silicone tubing relax inside the weather seal. If it works, I'll post about it.

 

I'm watching this thread. I am getting an '03 from a friend of mine, he got a new truck, and it has a leaking moon roof. He said it was the track mechanism and has purchased the repair parts but it will be my task to install/repair. Hoping you solve the problem.

 

I pulled and reinstalled my door seals and I never had this issue again. Could be the common issue of lack of seam sealer.