Overall Water Leaks Diagnosis And Testing

Water Leak Tech Tips and Repair Videos	Refer to A-PILLAR WATER LEAKS DIAGNOSIS AND TESTING VIDEO . Refer to A-PILLAR AND COWL WATER LEAK REPAIR TIPS VIDEO . Refer to B-PILLAR AND COWL WATER LEAK REPAIR TIPS VIDEO . Refer to B-PILLAR AND COWL WATER LEAK REPAIR TIPS VIDEO .
LOCATION	POSSIBLE CAUSES	CORRECTIONS
Water is on the A-pillar or side of the instrument panel	Freedom Panels Header Seal Doors Windshield Frame	Refer to FREEDOM PANELS CORRECTIONS . Refer to HEADER SEAL CORRECTIONS . Refer to DOOR CORRECTIONS . Refer to WINDSHIELD FRAME CORRECTIONS .
Water is on the front door trim panel of lower sill trim	Doors Freedom Panels	Refer to DOOR CORRECTIONS . Refer to FREEDOM PANELS CORRECTIONS .
Water is on the cowl side, floor board, or on the side of the instrument panel	Cowl Seal Cowl Grille/Plenum Cowl/Dash Body Side	Refer to COWL SEAL CORRECTIONS . Refer to COWL GRILLE/PLENUM CORRECTIONS . Refer to COWL/DASH BODY SIDE CORRECTIONS .
Water is on the center of the instrument panel or center of speaker bar	Freedom Panels Hard Top Seal Windshield Frame	Refer to FREEDOM PANELS CORRECTIONS . Refer to HARD TOP SEAL CORRECTIONS . Refer to WINDSHIELD FRAME CORRECTIONS .
Water Over Rear Sport Bar or B-pillar	Hard Top Seal B-Pillar Mucket Doors Freedom Panel	Refer to HARD TOP SEAL CORRECTIONS . Refer to B-PILLAR MUCKET CORRECTIONS . Refer to DOOR CORRECTIONS . Refer to FREEDOM PANELS CORRECTIONS .

Refer to WATER LEAK CONDITION INDEX .

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1. Check to verify the super mucket is not sitting too far outboard on the B-pillar. Press in with top fully secured to address this issue.

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2. Verify the feathered edge of the super mucket is not rolled underneath the panel or damaged.

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3. Verify the sure push pins are fully seated to prevent super mucket from traveling off position.

Refer to WATER LEAK CONDITION INDEX .

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1. Verify the seal (2) is seated down on plenum/baffle and that no abnormal rotation of the seal is observed around the sport bar (1).

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2. Check vertical foam strip on top of seal and large foam on side of seal for gaps or damage.

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3. Verify the cowl seal pins are fully seated. Pin (1) is seated correctly and pin (2) needs to be corrected. A mallet may be required to make sure pins are fully seated.

Refer to WATER LEAK CONDITION INDEX .

1. Mastic patch covering body hole found under door sill trim is hidden behind the wire harness. Remove trim and unbolt harness to check patch integrity.
2. Mastic patch on upper driver side inside engine compartment, partially covered by pad. There is also a twist lock plug directly beneath. Both can leak down dash wall if damaged or improperly secured.
3. Several welded studs and plates on dash wall can leak if a gap is present in the weld. Use clear sealer around stud and mastic over plates.

Refer to WATER LEAK CONDITION INDEX .

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1. The two outboard pins on the passenger side can allow water into the HVAC system. Verify the pins are not damaged and gasket is present and undamaged.

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2. Any damage to the foil/Mylar mastic patch (2) will create a leak and must be repaired. Verify the patch (1) is not too low on the back wall of plenum and check for holes and gaps around the sport bar.

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3. Check baffle cap (1) and make sure it is not damaged, broken, or off location. Replace the butyl chicklet (2) on the top side of the baffle any time the cowl seal is removed.
4. Sealer void at the plenum to dash to cowl interface. Using a paintable repair sealer Part No. 04318026AB or equivalent, repair as needed.

Refer to WATER LEAK CONDITION INDEX .

1. Adjust the doors to the correct locations, Refer to GAP AND FLUSH, SPECIFICATIONS .

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2. Verify the seal is in the proper position and all pins are properly seated.

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3. Check for skips, voids, or damage in the seal retainer sealer (1) and using a paintable repair sealer Part No. 04318026AB or equivalent, repair as needed.

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4. Verify the drain holes in bottom of seal are present and unobstructed.
5. Check to verify all the carrier plate bolts are properly tightened, Refer to PLATE, CARRIER, REMOVAL AND INSTALLATION .
6. Verify the door pad retainer clips are present and sealing properly.
7. Check wire harness push pins for damage and verify all pins are properly seated and sealed.

Refer to WATER LEAK CONDITION INDEX .

1. Set freedom panel gap/flush at front receivers, Refer to REMOVABLE TOP, HARD, STANDARD PROCEDURE .
2. Check for missing, damaged, or off location foam, Refer to REMOVABLE TOP, HARD, STANDARD PROCEDURE .

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3. Verify the freedom panel center seal is not damaged and in the proper location.

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4. The seal end molds will appear rotated if the seal is too far forward or rearward.

Refer to WATER LEAK CONDITION INDEX .

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1. Check alignment of hard top header seal to center seal of freedom panel. Verify the seal is not pinched between the freedom tops.

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2. Verify the center seal is flat against the header seal.

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3. If B-pillar super mucket leaks from upper feathered edge or over sport bar (water in hard top bolt recess) replace butyl between hard top header seal end mold and hard top.

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4. Verify seal is not off location cross car, leaving a large gap between the primary bulb of the seal and the B-pillar mucket. Finesse seal to minimize gap.

Refer to WATER LEAK CONDITION INDEX .

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1. Left hand spear foam

2. Right hand spear foam

3. 30 mm (1.2 in.)

4. 85 mm (3.4 in.)

5. 15 mm (0.6 in.)

6. 140 mm (5.5 in.)

7. 10 mm (0.4 in.)

Windshield Header Foam/Butyl Replacement (change to spear foam)

• Replaces usage of L-Foam, Butyl Chicklet, and Razer foam
• Improves manufacturability, water sealing, and wind noise capabilities
• 4 mm Ebony ESL 600 material
• Butyl backing (adhesive)
• LH and RH mirrored parts

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1. Using a small punch (2) or equivalent, remove the seal rivets (1) and lift the end of the seal out of the way.

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2. Remove L shaped foam (1), butyl patch (2) and lower razor foam (3) and clean all surfaces fully prior to installation of the new spear foam.

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3. Begin installation by placing the spear foam (2) onto the windshield frame.
   1. Start at the tip of the foam (1).
   2. Place tip into radius of windshield frame (1) as shown in illustration.
   3. Foam corner (3) sits parallel with windshield header bathtub (4).

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4. Seat the remaining foam around the header of the windshield frame maintaining a tight even gap to the forward edge of the frame (1).
5. Verify the foam is fully seated to windshield frame along the radius to avoid pocketing under the foam (2) that can allow water to pass.

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6. Verify the header seal (1) is positioned evenly side to side (2).

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7. Verify the header seal is fully seated in the windshield frame and foam (1) is not visible between frame and seal. If visible, pull end of header seal forward.

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8. Install the new rivets (2).
   NOTE:

   A slight bit of the spear foam should protrude from the lower feathered edge of the seal (1) when properly installed.

Refer to WATER LEAK CONDITION INDEX .

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1. Check windshield frame panel seam sealer (1) using shop air and soap test. Using a paintable repair sealer Part No. 04318026AB or equivalent, repair as needed.

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2. Check windshield urethane (1) for voids or gaps using soap and air.

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3. Check drain tube (1) for damage and make sure boot (2) is secured to drain trough properly.

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4. Check drain trough for sealer skips or voids with water bottle test.

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5. Inspect the trough end cap for sealer voids, cracks or damage.

Refer to WATER LEAK CONDITION INDEX .

Refer to WATER LEAK CONDITION INDEX .

Refer to WATER LEAK CONDITION INDEX .

Refer to WATER LEAK CONDITION INDEX .