Sunroof leak, not the tubes?

[R_Lefebvre]

I've read through everything I could, searched, but haven't found the answer yet. Nothing has addressed my problem, which doesn't appear to be the drain tubes.

Ok, I bought this 04 SE a few months ago, and while installing radio stuff, I found the carpet was soaked and the floor is rusty.

I went to the LR dealership as I still had a bit of warranty left. They said that they repositioned the sunroof drain tubes and resealed them. I'm not really sure what they mean by that. I could smell a solvent smell in the car, so they must have done something.

However, they also said I will have a remaining leak due to a crappy aftermarket windshield install that was not their responsibility.

I have proceeded to pull the car apart to fix this problem.

-I've got the carpets out so that they can dry and I can put some rust paint on the floor. I've also removed most of the interior trim.

-During a recent rain storm, the floor actually collected a little puddle of water. I can see it running down the metal behind where the kickpanel/deadpedal trim used to be. The headliner got wet on the front corners. Sometimes when turning a corner, water dripped out of the sunroof switch area.

So, I've established that after the LR repair to the drains, something is still happening.

-I've taken off the A pillar trim on the inside and outside so I can track down the problem.

-The windshield install does indeed look like a crappy install, however, I can't see how water could get past the TONS of goop they've got on there.

-I soaked the truck, starting from the top and working my way up. I used free flow from a hose, and sprayer, all around the windshield, and NOTHING came into the truck! I did the seals on the sides, the cowl area, the top, the sunroof, nothing came into the truck and pooled on the floor.

-I checked the drain tubes as best I could. I poured water from a jug into the sunroof tray. It gushed out the bottom of the truck as it should. Nothing came inside the truck. The drains seem to run free.

-I went to move the truck, and then water poured out of the upper trim/sunroof switch/rear view mirror area!

How in the heck is water collecting up there?

I'm going to start by dropping that upper trim, then maybe the headliner. But if anybody has any other ideas, it would be appreciated.

 

[sven]

Well since you've removed 1/2 the interior already you might as well drop the headliner. Chances are that whatever is broken (leaking) up there will require it to be removed anyways to fix.

Go for it!

 

[R_Lefebvre]

I was hoping not to have to drop the headliner, but it's seeming that way. I'm just hesitant... I've only taken the headliner out of a VW Rabbit before, and I had to glue it back up and it was never right again. From the sounds of it, the LR headliner isn't that bad?

 

[adriatic04]

headliner isnt that bad. i would be doing that right away, get it out and correct this issue and be done with it. just pull parts from the rear cargo and some minor trim pieces and then pull her out.

oh yea, get some of those little pins to have around as extra, you will probably break a couple.

 

[R_Lefebvre]

Can I drop just the front section? Just work around it? Or will it just crease?

My "luxury vehicle" is starting to look like a clapped out beater! :smilelol:

 

[Ataraxia]

I too have had (still have) a leak... soaked front of the headliner where it meets the windsheild and dripping from the sunroof switches.

here is a thread i started last year about this, and some people replyed with some helpful info.


http://www.discoweb.org/forums/showthread.php?t=41352

I ended up dropping the front half of the headliner without an issue. It's more time consuming than difficult. my drain tubes were not attached to the little (poorly designed) plastic nipples that totally unglued themselves.

I was told the rear could have the same issue and drain itself on the top of the headliner, all the way to the front...



Enjoy your long weekend :cheers:

 

[Ataraxia]

Yes you can drop just the front... it will hang down enough for you to do the repairs.

 

[R_Lefebvre]

I'm NOT working on this over the 2-4! :ack:

Tackling it this week. Want to get this all completed before the weekend so that I can take this up to the lake. I'd love to put the carpets back because it's ungawdly loud without them!

BTW, you might want to check your floors if you've had this problem. They may be rusty. The carpet has like an inch of rubber foam under it that really traps a lot of water, holds it right against the floor. Mines pretty bad, hopefully not structural yet. I am going to wire brush it and hit with some rustoleum before putting the carpet back.

Maybe while I'm at it, I'll wire in a water sensor under the carpet that lets me know next time it's leaking, before it's too late! :banghead: Either that, or a sump pump. :rofl:

 

[deeker]

Let us know what you come up with. This is something I'm experiencing, as well.

I didn't read the other thread that was linked, but I did read on another forum that one fellow had a crack between roof and windshield body panels that allowed water to seep in. His leak was on the pass. side up in the top corner of the windshield.

 

[adriatic04]

you can drop either front or back and have just enough room to work, but why not drop it all and get it all fixed up.

this is quickly turning into one of those issues that everyone has sooner or later. hopefully, when, not if, mine starts to leak I will be well versed :applause:

have a few bud heavy's around for moral support

 

[a2tripp]

where the glass on the sunroof meets the seal on the truck, pull that gasket and seal it from the metal to the gasket. this was my fix.

 

[Bannon88]

There are also 4 torx head screws (t-15), iirc, that secure the glass to the rails. Check to make sure these haven't come loose. I had one on the rear sunroof back out just enough to cause water to get in.

Drop the headliner, it's really not that bad. Keep your parts organized and take your time.

I also performed the headliner never sag again procedure of removing the foam and sanding the backing. Then painted it. Allowed to dry and replaced. I like it.

 

[R_Lefebvre]

I think the "never sag" business is only on a D1? I have a D2, the headliner seems well done.

I don't know what I'm going to do with those motherfuckers at the dealership once I prove that this is NOT the windshield. I wish I could bill them for my time. This is how you diagnose a problem, not fucking throw darts while blindfolded.

 

[R_Lefebvre]

Ok, I think I got this fixed. Last week I completely gutted the interior. The only trim left was the rear seat, cargo sides and carpet, and the dashboard. I saw the fix the dealer attempted on the sunroof. Looks like they took a plastic back, pumped a bunch of clear sealant on it, squished it up onto the plastic sunroof drain nipples and put the headliner back up. From the stains on the headliner underside, I could see that they had all leaked at some point.

I tried pouring water in again, and found out that if you pour too much water, all the drains will leak a little. Like they are sealed at the bottom, but not the top. I found one of them still leaked even with only moderate amounts of water. I gooped that up with RTV as best I can. Problem solved there.

I also determined that if you pour too much water, or presumably if your drain tubes are clogged, the water can build up in the trough until it comes out the sunroof motor mounting holes. That's why you end up with water coming from the plastic trim up there.

It doesn't appear to be an issue with reasonable amounts of water.

I also determined that I did indeed have leaks coming from the sketchy windshield install. I used a special runny silicone sealant and gooped those up. It flows into any places water will flow. That seems to have fixed that.

<knock on wood>

 

[ajh]

Mine was due to the top seal leaking, the pan filling up, and because I park in my driveway which is an incline it would get through the holes used to fix the blinds in place before it would get to the drain tubes mounted in the front of the tray.

If you're doing the same try parking nose-down vs nose-up and see. I put silicone in the holes and haven't seen the problem since. (well once ice formed in the seal and expanded it, but cleaning out the V in the seal and it worked again)

 

[DOHC Holliday]

I had one leaking around the frame. I resealed with 3M weatherstrip adhesive between the roof and factory gasket material and it solved the issue.

It's honestly a simple job. Can be done in less than a few hours with basic hand tools and some upholstery tools. Having an extra set of hands and eyes while getting the headliner out of the vehicle does make it easier though.

Also... The first time I had a leak I found debris between the window and gasket. I went up on the roof with a shop vac, soapy water and a brush and made sure all mating surfaces were clean.

 

[Tempest]

I used a special runny silicone sealant and gooped those up. It flows into any places water will flow. That seems to have fixed that.

Do you remember the brand/name and is it still not leaking?

My wife noticed a drop running down the side of the A pillar on the pass. side... once it dried out I took a look at the corner of the roof and front windshield and noticed a gap/hole... took the hose... ran water on it and sure enough the corner headliner instantly got wet. So I want to seal it properly by plugging the hole up and without ruining the rest of the rubber seal around the window.

Thanks

 

[R_Lefebvre]

It was Permatex. It's hard to say if it's still sealed or not, since it's Air Con season and my evaporator is constantly pouring water onto the floor. :banghead:

Yes, I've tweaked my nipples. I did it about a month ago, and got the gush of water from one of them. I'm not sure what's up with this now because it's still happening. Last time it happened it was when I turned a left corner harder than I ever have before in this truck. My wife said water poured out the floor vents. :banghead:

 

[Beard]

i park nose up a very very slight incline.. if i immediately back the truck up a dcent incline i get some leaking on the driver side frame rail of the sunroof.. i cant figure it out.

 

[Tempest]

Yes, I've tweaked my nipples.

S&M eh? :rofl:

Thanks for the info, re: permatex and additional frustrations. Here in FL it is almost always air con season... or raining in the afternoons... and wife has had water dumped on her feet before as well.