Leak at Upper Windshield Corners

[sscott3d]

After letting the sealant cure I gave her a good soaking with the hose. No more leak! I've been chasing this leak for quite awhile so it was a nice win. I tried posting some pics this am but am having some issues getting a new phone with the pics on it to sync with my laptop. On the schematic I sealed where panels 3, 6, and 8 come together in the corner inside the rain gutter and also under the rain gutter where it meets the fire wall panel 8. I think under the gutter was root of the problem right next to the boot for the windshield wiper motor wires. This seam is pretty much impossible to see and not easy to get to. Its above the main wire harness connectors going through the fire wall. In my case the leak would appear when I spayed water above into the gutter and also from below on the fire wall. But I think what was happening is the wiper boot was leaking from the gutter above to the seam making it hard to pinpoint. I'll keep trying with the pictures but I honestly don''t know how much help they'll be. It's hard to get a reference in such a tight spot.

[JWA]

Originally Posted by Railvan

Interesting and timely thread. My 2006 SMB has never had wet carpet in front of the driver's seat until this winter, and I had the front windshield replaced last spring. The van is not garaged so it seems it leaked during the winter. I assumed it was leaking due to poor sealing when the new window was installed. Now I'm trying to visualize where this leaking body seam is that is the focus of this thread. Thanks for of the effort people put into these threads.

If your leaks were discovered only after a new windshield was installed that would be my first point to check. Its not impossible for one of our E-Series to develop an actual body leak over time but your case the cause & effect strongly suggest its the windshield leaking.

There should be a few suggestions in this thread alone helping you isolate your leak. I'd start there before thinking the body itself is at fault.

Who did the installation?

[arctictraveller]

Originally Posted by sscott3d

After letting the sealant cure I gave her a good soaking with the hose. No more leak! .

Congratulations, Leaks can be really difficult to reproduce and damn near impossible to find. Glad you found it. Where are you located? We spend a lot of time in the islands.

[JWA]

Originally Posted by sscott3d

I'll keep trying with the pictures but I honestly don''t know how much help they'll be. It's hard to get a reference in such a tight spot.

A photo showing the general area your leak was suspected would be helpful too.

As I said earlier I've almost never heard of a leak in the area you're describing---for me it would be another point to check/test if I encounter a leaking E-Series during my replacement work.

TIA

[Bbasso]

Reputable glass shop will investigate a water leak have them come by or go to them and let them investigate the water leak if you strongly suspect it's your windshield

[Drizzt]

The schematic JWA had is better than any other I've come across, but I finally gave up after getting another warning for having a vehicle torn apart in my drive and took it to my local diesel shop. They maintain a couple of van fleets and said they've seen the seam problem before but it's usually appears while a van is still newish, like a couple of years. They have the insulation, e-brake and fuse box pulled and are applying epoxy in the corner. We'll see if this solves the issue. I didn't think to take a picture because I'm a dummy.

It was funny when I rolled into the shop. These guys are also a diesel rod shop and build some custom 4x4 stuff and hadn't seen my van since the U-Joint conversion. Pretty much the entire shop emptied out to come look all over it when I got there.

[JWA]

Originally Posted by Drizzt

I didn't think to take a picture because I'm a dummy.

It was funny when I rolled into the shop. These guys are also a diesel rod shop and build some custom 4x4 stuff and hadn't seen my van since the U-Joint conversion. Pretty much the entire shop emptied out to come look all over it when I got there.

No biggie on the photo---would be nice to see mostly out of curiosity at least for me.

Its cool the shop wanted to see your van---that says to me they might enjoy finding and solving your leak---good move I'm thinking!

[sscott3d]

I haven't given up on posting the photo's yet. Just busy and not very tech savvy. It's going to take a little time but get them posted
For me it was easier to seal from the outside (engine bay). I could feel a raised pinched spot in the seam.
Arctic I'm on San Juan Isl. Love it here! Sometimes it makes getting van parts a challenge though.

[JWA]

Good enough SScott3d!

[sscott3d]

so here's the pics I've been trying to post. Sideways and all I figure better than nothing. The first is inside the "rain gutter" top by wiper arm. Second is underneath gutter shelf right above main wire connector going through the fire wall. Third is fender off which didn't reveal any hidden body seams. last is just floor board where water was pooling. Kind of out of order but I hope this helps.