Originally Posted by BIGVANS
Ford had a bulletin out on this, itís about the epoxy not sticking and the paint along the rain gutter not sticking. They had an updated epoxy and they also fought tooth and nail to NOT repair it under warranty.
What years did this affect? I don't think my 2008 is hard like I think epoxy would be. I think its more like typical flexable seam sealer.
My van has/had a factory body defect ever since it was new (well two as it also has a small dent in the rain gutter under the paint) The left rear area from the bottom of the upper rear door hinge down and around to the rear lower quarter panel did not have any spot welds. Basically the spot welding machine must have broken or something when they were welding the quarter panel to the inner body. Its missing maybe one hundred spot welds as well as a complete small triangle panel that goes from the quarter panel to inner fender joint and then up to the rear of the body. When it was new (and before I bought it) it leaked water around the door area so the dealer did some plug welding and seam sealer and touched up the paint but never did anything about the other missing spot welds, missing part or the big gap in the lower quarter panel where the part is missing. I bought the triangle panel a year and a half ago but have never done anything about installing it. The factory paint is so nice I hate to mess with it by blending it. Maybe someday when I build or buy bumpers for it I will grind it down, weld the missing panel in and paint the area behind the bumper with semi gloss black or bed liner paint and have a tape line. I think the repair is ugly but there is no easy way to get it to look like the stock spot welds after it was assembled no matter what. It could look better if I scraped out the messy sealer (it even has some finger prints in it) and re applied it neater and then touch up the area.
SCBrian, I will look at my roof sealer but I think it is ok. I would like that repair more than having the windshield redone.
I would think that some urethane would repair it. Just try to see if there is anythjng still loose and then force a small amount into the area. After you are sure it doesn't leak just use touch up paint to hide the repair.