Door - Water Leaks Onto Front Floor
Article No.99-21-5
10/18/99
WATER LEAK - WATER LEAKS ONTO FRONT FLOOR
FROM DOOR PANEL AREA
FORD:
1998-1999 CONTOUR
MERCURY:
1998-1999 MYSTIQUE
This TSB article is being republished in its entirety to include 1999 model year vehicles and to revise the Service Procedure.
ISSUE
Water may leak onto the front floor area adjacent to the front door. This is may be caused by water leaking around the front door polyshield due to incorrectly installed polyshield.
ACTION
Determine how the water is entering the vehicle and either replace the current polyshield or apply a butyl seal around the speaker. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
DETERMINE PATH WATER ENTERS VEHICLE
1. Remove the door trim panel.
2. Run water onto the outside of the closed door.
3. If water is coming through the bottom of the polyshield then it is likely the polyshield is incorrectly aligned or installed over the metal drain holes; go to Section A. If water is detected around the speaker, go to Section B. If neither A nor B, perform normal diagnostics.
SECTION A
1. Remove the old polyshield.
2. Clean the sheet metal surface of any residue remaining from the removal of the old shield using a putty knife and/or solvent material.
3. Repair any paint marrs.
4. Clean the surface of the inner door panel along the adhesive path with rubbing alcohol or equivalent.
5. Cut two (2) 30 mm (1.25") square patches from the D9AZ-5420552-BA butyl.
6. Apply the pre-cut square butyl patches to the drain holes on the inside of the door (Figure 1).
7. Take the new Polyshield (F8RZ-54237A04-AA right door, F8RZ-54237A05-AA left door) and remove the masking from the adhesive immediately prior to applying the new polyshield to the door.
8. Align the polyshield along the lower surface of the door such that the adhesive DOES NOT CONTACT the door panel inner attachment clips, and that it is below the drain holes as shown by the dotted line in Figure 1.
NOTE
BE SURE THE ADHESIVE BACKING IS NOT WRINKLED OR KINKED AND FREE OF DIRT OR WATER. IT IS VERY IMPORTANT THAT THE BOTTOM OF THE POLYSHIELD IS STUCK TO THE METAL AND CLEAR OF ANY CLIPS OR HOLES WHICH WOULD PREVENT THE SHIELD FROM LYING COMPLETELY FLAT ON THE METAL.
9. After the polyshield is applied to the door, press the lower part of the polyshield flat with a paint roller or similar device to ensure the seal is pressed into place securely.
10. Go to Step 2 of "Determine Path Water Enters Vehicle" and repeat the water test to be sure there is no more leakage.
11. Reinstall the trim panel.
SECTION B
If there is evidence of water around the speaker (traces of water around the speaker are not detrimental) and there is a path of water which is draining onto the floor, then:
1. Remove the speaker from the opening.
2. Disconnect the wire and lay the speaker on an appropriate surface so it will not get damaged.
3. Cut one (1) 12 mm x 75 mm (0.5"x3") patch from the D9AZ-5420552-BA butyl.
4. There are two (2) small drain holes and one larger drain hole along the lower cavity of the speaker. Apply the pre-cut patch along the bottom of the speaker so it will seal the two small drain holes in the speakers but not completely cover the larger hole (Figures 2 and 3).
NOTE
THE PATCH WILL NOT FULLY COVER THE LARGER HOLE AND IS NOT INTENDED TO AS THIS WOULD PROHIBIT WATER FROM DRAINING FROM THE SPEAKER CONE (FIGURE 3).
5. Reinstall the speaker.
6. Go to Step 2 of "Determine Path Water Enters Vehicle" and repeat the water test to be sure there is no more leakage.
7. Reinstall the trim panel.
PART NUMBER PART NAME
F8RZ-54237A04-AA Polyshield - Right
F8RZ-54237A05-AA Polyshield - Left
D9AZ-5420552-BA Butyl Patch
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 98-18-12
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
992105AB Install New Polyshield On 1.3 Hrs.
Both Doors
992105A Install New Polyshield On 0.7 Hrs.
One Door
DEALER CODING
CONDITION
BASIC PART NO. CODE
54237A04/54237A05 D8
OASIS CODES: 110000