Windshield Header - Water Leaks To The Interior
88chrysler02 ModelsAll C-G-H-J-P & S Bodies
Subject
Windshield/Drip Rail/Drain Trough Water Leak Diagnosis & Repair
Index
BODY
Date
February 29, 1988
No.
23-01-88
P-681 (C23-01)
SYMPTOM/CONDITION
Water entering the inside of vehicle at the roof header (sun visor) area.
FIGURE 1:
DIAGNOSIS
Water test the vehicle, using a 3" stream of water to determine point of water entry. Determine if water is entering the vehicle at the roof header area in one of two ways:
1. Water passing between the glass and the sheetmetal flange (Figure 1). This would be considered a windshield water leak. Proper diagnosis can be determined by localizing the water flow to just the windshield. A help would be to apply a soap solution to the outer windshield edge and apply medium pressure shop air, from the inside edge of the glass, to pin point the leak entry point.
2. Water passing between the sheetmetal glass attaching flange and the header reinforcement flange (Figure 1). This type of leak would be considered a drip rail water leak. Proper diagnosis can be determined by localizing the water flow to just the drip rail area. Constructing a dam with strip caulk (dum dum) is helpful to isolate the location of the leak.
The water flow at the drip rail area will require a longer period of time for the leak to appear. This type of leak is elusive, and may require positioning of the vehicle on a frontal downward slope, or driving and turning the vehicle right or left to duplicate the water leak.
REPAIR PROCEDURES
The following procedure outlines the method of correcting water leaks by resealing the windshield or drip rails of the vehicle.
Windshield Reseal
Exterior windshield molding on subject vehicles cannot be removed without damage occurring. You may, however, be able to seal the glass from the outside by using a flowable silicone sealant such as Windshield and Glass Silicone Sealant, PN 4467708, or Urethane Sealer, PN 4318023.
Clean the blow dry area of windshield glass flange to be sealed. Apply either Windshield and Glass Silicone Sealant, PN 4467708, or Urethane Sealer, PN 4318023 to the suspect area. It may be helpful to use a trim stick to open a gap for better access to the area to be sealed. Clean up excess sealer and allow to cure.
The same sealers may be applied from the inside of the vehicle by pulling the front portion of headliner down.
NOTE: IN ALL APPLICATIONS OF AIR DRY AND/OR URETHANE SEALERS, ALLOW ADEQUATE TIME FOR SEALERS TO CURE AND THEN WATER TEST FOR RESULTS.
FIGURE 2:
Drip Rail/Drain Trough Reseal
Remove secondary rubber seal from attaching flange. Inspect drip rail top/ bottom, and especially the rear end portion for potential sealer skips/cracks/pin holes. Apply Clear Air Dry Sealer, PN 4318026, to the repair area (Figure 2).
The forward portion of the roof to aperture joint may also be susceptible to leaks. Isolate, water test, and check for sealer skips. If leak appears, then repair requires interior headliner and outside molding removal for access to the sealer joint. The above air dry sealer should then be used.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE: Existing Labor Operation
Labor Operation No. 23-50-25-01 . . . . . . . . . . . 0.5 Hrs.
Windshield Reseal
23-50-55-02/03 . . . . . . . . . . . . . . 0.2 Hrs. Drip Rail/Drain Trough Reseal
FAILURE CODE: 51 - Improperly Installed
65 - Leaks
7X - Weld Defect
78 - Split Metal or Pin Hole
91 - Sealer Omitted or Skips