Body - Water Leaks to The Interior
NUMBER: 23-027-06GROUP: Body
DATE: July 02, 2006
SUBJECT:
Passenger Compartment - Water Leak Diagnosis
MODELS:
2006 (ND) Dakota
DISCUSSION:
The customer may experience a water leak in the passenger compartment. This leak may cause the front carpeting on the driver or passenger side to become wet. The source of the leak may be difficult to diagnose. Refer to the following information to assist you in diagnosing the water leak.
Additional assistance may be obtain by accessing the 2007 ND (Dakota) Service Information on TechCONNECT. Select the Service Info tab then: 23 - Body > Body Structure > Sealer Locations > Specifications > Sealer Locations.
A. Water Is Entering From Cowl Side / Dash Area
If water Is entering along the cowl side to dash panel seam (Fig. 1).
Possible Cause and Solution:
1. Check for sealer skip along interior cowl/dash panel seam (Fig. 2).
a. Repair by adding sealer to the skip area along the seam.
2. Check for sealer skip along the "Dog Leg" on the outside of the vehicle (Fig. 3).
a. Repair with sealer along the entire flange. The fender stuffer needs to be moved rearward. The wheel liner may need to be removed to access the skip (Fig. 3).
B. Water Entering Through Holes In Cowl Side
If there is a sealer skip, water may enter in three (3) locations that will fill up between the aperture and cowl side and enter the interior of the vehicle in either of these two (2) following locations:
a. Water entering along the seam between the floor pan and the side cowl (Fig. 4).
b. Water entering through the tooling hole in cowl side and/or the floor aperture side hole (Fig. 5).
Possible Cause and Solution:
1. Check for a sealer skip in the "Dog Leg" (aperture/cowl side / dash panel) (Fig. 6).
a. Repair by adding sealer to the skip area along the seam.
2. Check for a sealer skip at the top of the cowl side to aperture joint (Fig. 7).
a. Repair by adding sealer to the skip area along the seam.
3. Check for a sealer skip inside of the plenum under the cowl screen.
a. Repair by adding sealer to the skip area along the seam. Use a long extension tube to apply sealer as necessary (Fig. 8).
C. Water Entering Along Floor Pan Area
There are 4 other non-sealer areas that water can originate from and appear to be a cowl side sealer skip (Fig. 9):
Possible Cause and Solution:
1. Check all four (4) sunroof drains (if equipped).
a. Remove headliner and inspect drain tubes and connections. Secure if necessary.
2. Check the primary door seal to make sure it is fully seated on the flange (Fig. 10) and (Fig. 11).
a. Repair by removing and reinstalling the weatherstrip. The weatherstrip does not need to be replaced unless it is damaged.
3. Check for a sealer skip along the back of the cab.
a. Repair by adding sealer to the skip along the seam (Fig. 12).
4. Check for water coming in from the door water shield.
a. Remove the door trim panel and make sure the butyl bead is sealed around the entire perimeter of the trim panel. The water shield does not need to be replaced (unless it is damaged) (Fig. 13).
D. Water Coming In Along The Dash Panel/HVAC
NOTE:
This leak typically will be induced by the vehicle being on an incline and/or during acceleration and show up on the floor (Fig. 14).
Possible Cause and Solution:
1. Check the HVAC inlet adapter to be sure it is secure.
a. Repair by properly securing the adaptor to the opening. A new adaptor may be necessary if the attachment clips are broken. The Instrument Panel and HVAC unit will need to be removed to access this area (Fig. 15) and (Fig. 16).
2. Check the plenum drain flap for correct installation.
a. The flap should be on the outside of the vehicle, thus allowing water to drain out. Repair by pushing the flap outward. The flap can be accessed by removing the cowl grill (Fig. 16) and (Fig. 17).
3. Check for sealer skip along the edge of the A-Pillar gusset (Fig. 15) and (Fig. 18).
a. Repair by sealing the open seam.
E. Water Entering Through Grab Handle Holes
Possible Cause and Solution:
1. The screw shown below (Fig. 20) can allow water to enter into the sheet metal cavity and come in through the grab handle screw holes (Fig. 19). There has been a change to remove this fastener (vehicles built on or after March 10, 2006 - MDH 0310XX). The clear tape will remain until the hole in the sheet metal is removed (vehicles built on or after May 1, 2006 - MDH 0501XX)
a. Remove secondary seal. Repair by adding clear sealer around the fastener (Fig. 20).
POLICY:
Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.