Removable Roof Water Leaks Along Windshield Header

1. Verify the two (2) roof T40 a-pillar attaching screws are torqued to 9 N.m (80 lb-in) and that latch handles below the porthole windows are fully engaged.

2. If fasteners are found loose or latches were not engaged, tighten/latch then water test.

a. If leak is repaired, return vehicle to customer.

b. If leaking continues proceed to Step 3.





3. Isolate source of leak by first applying masking tape over the windshield header seal. The masking tape should overlap onto the chrome windshield header molding and onto the roof header trim bead (Figure 9).

4. Remove the interior header trim panel from the removable roof by grasping and firmly pulling down the panel. This will aid in locating the source area of the water leak.

5. Run normally pressurized tap water from a standard size garden hose over the taped off area.

a. If the leak is no longer present proceed to Step 6.

b. If the leak is still present proceed to Step 12.

6. Remove the removable roof.

7. Inspect windshield header seal for damage.

a. If seal is damaged repair as necessary and perform water test. Return vehicle to customer if leak has been repaired.

b. If seal is OK then proceed to Step 8.

8. Remove the chrome windshield header molding and the left and right chrome a-pillar moldings and inspect seams in windshield frame (refer to Workshop Manual Section 501-00 for removal instructions).

9. Seal seams as necessary with Silicone Gasket and Sealant, part number TA-30.

10. Reinstall chrome windshield header molding and the left and right chrome a-pillar moldings.

11. Reinstall the removable roof and verify the repair.

a. If leak is still present proceed to Step 12.

b. If leak is no longer present return vehicle to customer.





12. Apply masking tape over removable roof to roof header trim bead seam and over removable roof to drip rail molding seam (Figure 10).

13. Run normally pressurized tap water from a standard size garden hose over the taped off area.

14. If water is not entering the vehicle during this test, it may be penetrating between the removable roof and roof header trim bead or between the removable roof and the removable roof drip rail molding.

15. Remove the roof and carefully set on the removable roof storage cart.





16. Check that the weatherstrip corners at the top of the a-pillars near the windshield header weatherstrips are seated correctly (Figure 11).

a. If gaps are present, correct by pushing/repositioning the weatherstrip as needed. Reinstall roof and water test. If leak is corrected return vehicle to customer.

b. If weatherstrips were seated correctly, proceed to Step 17.





17. On the side where the roof leak is present (RF or LF corner), loosen screws on the underside of roof that attach the roof header trim bead (Figure 12).





18. Starting on the top side of removable roof, apply a small bead of clear silicone rubber, part number TA-32, between the roof header trim bead and the removable roof starting in the corner where the leak is inward about 20.5 cm (8") toward the center of the roof. (Figure 13).

NOTE
USE A SOFT FLEXIBLE PLASTIC OR RUBBER PADDLE (SUCH AS A BODY FILLER SPREADER) TO GENTLY LIFT UP ON TRIM MOLDING WHILE APPLYING THE SEALANT BEAD.

CAUTION
DO NOT USE TOOLS TO DIRECT THE SILICONE THAT WILL DAMAGE THE PAINT. TEST TOOL ON A SCRAP PIECE OF PAINTED SHEET METAL FIRST TO CHECK FOR EVIDENCE OF PAINT DAMAGE.

19. Immediately clean the excess silicone from the roof with a damp cloth.

20. Repeat application of clear silicone rubber, part number TA-32, between the drip rail molding and removable roof starting in the corner where the leak is back to about the point where side window starts to curve down at b-pillar (Figure 13).

21. Immediately clean the excess silicone from the roof with a damp cloth.

22. Working on the underside of the removable roof, apply a small bead of clear silicone rubber, part number TA-32, between the roof header trim bead and the removable roof (Figure 12).

23. Retighten the roof header trim bead screws that were loosened in Step 17 of this procedure (Figure 12).

24. Secure rubber flap down on underside corner where leak is of removable roof with Ford Trim and Weatherstrip Adhesive TA-14 (Figure 12).

25. Reinstall the removable roof and reset the power window short drop function. Refer to the Owner's Guide.





NOTE
MAKE SURE THAT THE REMOVABLE ROOF HAS THE PROPER 7 MM GAP BETWEEN THE CHROME WINDSHIELD HEADER MOLDING AND THE REMOVABLE ROOF (FIGURE 14).

26. Water test with normally pressurized tap water through a standard size garden hose to verify the repair.