The Repair Lasted Exactly One Rainstorm

[BadlandsA51]

Thanks for the feedback. Just to clarify, I haven’t removed the roof panels a single time since I got the Bronco back from the dealership after they had it for six weeks replacing the front header seal. That’s actually the whole reason I’ve been documenting this. The very first rain after the repair, with the roof exactly as the dealer returned it to me, it leaked again.


As far as the multiple posts, that was actually suggested to me. I was told I needed to get a second opinion, so I figured I’d get more than just one. There are a lot of experienced Bronco owners and technicians on these forums, and I’ve received some really helpful information that I wouldn’t have gotten otherwise.


I appreciate the suggestions about the flashlight and dollar bill tests. At the same time, since the vehicle is still under warranty and the dealer has already attempted one repair, I’m trying to let Ford diagnose and document the root cause rather than start disassembling or modifying anything myself. My goal isn’t to complain—it’s to understand what’s happening and hopefully help Ford get it fixed the right way.

Dealer can’t find a water leak and spent SIX WEEKS looking for it?!?! You need to find another dealer. It’s not that hard!

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[flip]

Thanks again for the detailed explanation. You seem to have firsthand experience with these roofs, so I have one technical question if you don’t mind.


In my main video, it’s hard to tell from the camera angle, but I was watching it closely during the test. Within about 10–15 seconds of turning the hose on the roof, water was already flowing out of the drains on both sides of the front header seal.


Is that amount and speed of water entering the header cavity considered normal? My concern isn’t that the drains are clogged—it’s that I believe too much water is entering the header cavity too quickly where the two front roof panels meet the header seal, rather than being diverted away by the sealing surfaces.


Does that sound like expected behavior, or would that make you suspect an issue with the header seal or the fitment where the front panels meet it? I’d really appreciate your opinion since you seem to have firsthand experience with these systems.

If water if flowing out of the drains and reservoir is draining, no water coming out of A pillar, then they are probably clear and flowing as much as they can. Now, the point you are getting to, is if the panels are properly positioned and seals are directing water to or away from the header seal. It's possible water is getting under the header seal and following the glass frame either getting behind sun visor trim and finally exiting at the A pillar trim or one of the other seals is out of position.

Not knowing exactly what the other dealer did keeps me from speculating but at this point what needs to be done is checking panel alignment and correct anything not right including seals. After that, pull the windshield and A pillar trim, put a hose on it and try to find the source of the intrusion. The header seal uses a bunch of butyl (3M rope seal) around the fasteners in the channel along with some other spots so it's possible that is still the problem even though a new seal was installed.

Water, air, noise, exhaust leaks can really suck to diagnose and more times than not are in the hours to locate and fix or take multiple visits. Attached is a pdf of the 4 door roof panel alignment from the workshop manual. Another thing that might help is having another bronco available to compare fitment of panels, gaps, seals, etc. rather than just going by what the book says. I'm a visual type of learner and seeing something, especially comparing apples to apples, informs more than words and pics on a screen.