cab leak

[machman]

Hello all, I have a 95 swb that has a water leak on the driver side I cant seem to find. Every time it rains, the driver side firewall insulation bottom edge gets wet and seeps into the carpet. I had a leak issue in the past at the upper roof seam sealer location that I fixed with more sealer. This was the first place I checked and it was ok. Its only the driver side. Any ideas on where to look first? I guess I can run the garden hose on it for starters and look under the dash. How hard is it to remove the cowl panel if it comes to that?

 

[m78]

Check out my repair on the Bronco II leak. Its older so it might not be the exact same, but maybe close. http://www.fordtruckfanatics.com/forum/showthread.php?t=21127&highlight=cowl+leak

 

[Fellro]

The windshield seal tends to let loose and leak somewhat often... only fix for this case is to take out the windshield and reseal.

 

[machman]

I put the garden hose to the cowl vent panel and found my problem. With the carpet pulled up I was able to see a stream of water running down from above the ecm location. It looks like I will be removing my cowl panel to seal up whatever I can find. It is definately coming from under there because that is the only place I applied the water to. I just hope I can get in there to seal it up. It looks pretty tight under the dash with the e-brake mounted to the dash mount casting. If I can get to it from the cowl side that would be good. Ill just have to dig in and see what is going on.
Any tips or suggestions on what sealer to use? The Ford manual says to use liquid butyl. Could windshield urethane be used instead if I cant get butyl?

 

[machman]

Hey M78, Where did you get the rubber sealer you used on your Bronco?

 

[DNFXDLI]

You could go with a seam sealer

http://www.eastwood.com/autobody/seam-sealer.html

 

[m78]

Hey M78, Where did you get the rubber sealer you used on your Bronco?

I used the plastic dip that coats tool handles. Thinned it out slightly to allow it to flow into the seam.

 

[machman]

Well, I pulled my cowl panel and found my leak. The factory seam sealer let loose and a rust hole formed about 2 inches long at the seam. I used a whole can of rust converter and then smeared a load of urethane over the hole and covered that with some brushable seam sealer. Been dry ever since.