[KA06GT]

Hey everyone,

Developed a small problem after having a monsoon's worth of rain all week.

I have a leak behind my dash that's running mainly into my passenger side floorboard and just a small trickle into my driver floorboard.

Now I know what you're thinking, but I have removed both cowls per the TSB and both of my drain plugs and cowl channel were completely clear (also changed my cabin air filter while in there). Also, I have followed the other TSB about the two outer grommets, the one directly above the SJB on the passenger side and the one above the amps on the driver side. All of those check out fine.

It seems to be coming from somewhere behind the center dash, basically somewhere right behind the radio. Now I haven't pulled the dash out yet, but is there anything back there that could allow rain water to come into the cabin?

I don't think it's the heater core, due to the fact that it only happens with a heavy downpour. My heat, defrost, and A/C all function perfectly, and it's pure rainwater coming out with no hint of anti-freeze that I can tell.

Is there anything I'm missing or has anyone else experienced a similar problem?

One last question, what's the best way to dry out the carpet and pad without having to pull the interior? I was thinking pulling out the front passenger side as far I could and maybe setting a fan down on it for a few hours and then going over it with a shampoo carpet cleaner then drying that out with a fan. Any chance of having a musty smell left over or have a chance of mildew?

 

[s197gt]

Do you have this TSB ? Pay close attention to colored pics, which help show all places water can enter cabin of car behind dash. Never, never remove dash to fix a leak....always leaks can be found and fixed without removing dash...just takes time.
Do also pay attention to pressurizing cabin test...which helps in some cases....yet best helps with leaks around front and side windows, not behind dash.
A thorough look at both the tech illustrations AND the pictures (figs 7&8) in TSB helps a person understand all the places where water could possibly enter cabin behind the dash. Any water entering the 'cowl channel' (fig 7) is going to get into the interior cabin of the car.
Water can also enter the 'cowl channel' through poor sealing of the 'forward pinch weld' (actually three pieces of sheet metal spot welded to each other here...top of cowl/firewall...with factory sealer which often fails to seal). This is a place to check if you are first sure none of the 10 grommets under cowl plastic covers are leaking. Forward pinch weld can be resealed with urethane sealer....same can be done with grommets, rather than replacing grommets. This sealer purchased at a Home Improvement store in a caulking tube much cheaper and good enough, rather than from a Ford store....about $5.
Final area where water can enter is poorly sealed areas of welds behind front fenders, both left and right sides of car....but this is a last resort place to look after all other areas have been checked out...as this would require removing fenders.

Water leaks within body weld areas very common on 05 And 06 models. Get used to it, as there will be more as car ages...and sealer fails, cracks. One must look at the overall picture. These are very good cars with many minor problems...very few major problems.

Also, the padding under the carpets is glued to carpet. Easy to pull it off the bottom of carpet, remove padding to dry outside of the car. Carpet can be dried in car, with space heater or the car's heater. Easiest to thoroughly dry both carpet and padding is to have them separated. Padding can be reinstalled after it's dry, no real need to glue it back in place.

Any chance windshield has been replaced ? A poorly sealed windshield can leak either water or air or both.

 

[KA06GT]

Thanks for the reply s197gt,

Sorry about the confusion. By taking apart the dash, I meant pulling the radio and climate controls out and seeing if there is any visible places for water to come though behind the vent area.

That one you linked is the TSB I followed, the other I could find but the actual TSB too, but basically followed this thread to a T just to rule this out as well,

http://www.allfordmustangs.com/foru...com/forums/2005-2010-mustang-talk/301555-pics-vid-2005-dash-water-leak-fix.html

It was getting dark, so I didn't get a chance to check the cowl panel to bulk head pinch weld super well but I'll take it back apart this weekend in the light and apply some of the Motorcraft Seam Sealer to it just to be safe, but I checked everything else in that TSB and thread posted above and it was all good.

It started raining again early this morning but not as heavily, and I was greeted with more water in the passenger side floorboard when I opened my door to head to work. I've attached a few pictures so you can get a better idea of where I'm talking about

 

[beartracks]

How to fix it.

Open the hood, locate two drains (rubber booties). One on each side down kind of low. Mine were clogged with small leaves and debris.

 

[KA06GT]

How to fix it.

Open the hood, locate two drains (rubber booties). One on each side down kind of low. Mine were clogged with small leaves and debris.

Thanks for the reply beartracks, but that was the first thing I did.

"Now I know what you're thinking, but I have removed both cowls per the TSB and both of my drain plugs and cowl channel were completely clear (also changed my cabin air filter while in there). Also, I have followed the other TSB (the thread I linked above) about the two outer grommets, the one directly above the SJB on the passenger side and the one above the amps on the driver side. All of those check out fine."

Now at this point I have also applied Ford Motorcraft Seam Sealer along all of the bulkhead pinch weld and also around all of the grommet clip holes that hold the cowls in place.

This morning was the first time it has rained since I did all that last weekend, but alas, there was a small bit of water in passenger floorboard again.

I suppose at this point I'll just need to pull the radio and climate controls and see if I can see any visible paths for water to enter and have someone pour water on the lower part of the windshield, cowls, and hood and see I can see where its coming from.

This is driving me nuts!

 

[beartracks]

My next best suspect would be the windshield seal. Maybe the plastic panels that cover the cowl.

 

[Garyalpusa]

I have an 05 that sat out this past winter. Its now being used to build a track car. When I totally stripped the interior the pass side had water oon the floor and the rug was soaked. I looked under the foam and rubber cover that goes up the firewall and found a 1 inch hole that did not have a grommet or anything sealing it. I bought this car and never drove it so I dont know if it has been a problem. I think the ony way to get under that mat is to remove the entire dash and the hvac box. Bummer.