Windshield cowl fluttters

[CalvinT]

I pulled up the windshield cowl to run some wires. I think I have it back down. All the clips in front seem to be snapped in and the weather strip is firm against the windshield. The cowl flutters from wind when I get over 35 mph or so. I taped the front down on the right and left sides and the noise went away. The front seems loose when I tap on it. Also the noise goes away if I tape it down about a foot from the hood hinge on each side (gaffer tape).

Obviously something is different. The cowl doesn't seem warped. Any ideas what I can check? If I tap on the top of the cowl on the right side it seems to be hitting something. Not sure what it could be. I'll be at the dealer today for the shock recall. It will give me a chance to look at a new Bronco and compare the cowl.

I'm open to ideas and suggestions. Glue is out. I'll probably remove the cowl on Friday and reinstall it. Any tricks I should know? Anything I should look for?

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[4x4TruckLEDs.com]

The cowls on these Broncos suck. We had ours replaced under warranty because it was not clipping in and was warped. Almost every Bronco we see come in here has some warpage or the cowl sticking up in some parts. They just DON'T clip down properly.

This is why we recommend customers use our A-Pillar brackets for their lights. While not NEEDED it helps sandwich the cowl down under the lights which helps keep it in place. That does not help for the center part though which is USUALLY where things are popping up.

No answer or solution, other then take it to Ford to get replaced.

 

[PWillette]

As mentioned above, the cowls suck. Early on there were many issues w/ warping and poor fitment...thought it had been figured out. I had issues getting mine reseated when installing ditch lights. The clips really do suck to get reseated.

 

[Valhalla]

My 23 is fine, did you have the issue before removal? If not, this isn't a ford issue it is a removing a one-time snap wore it. I'd say remove, inspect if all looks good then use felt or something to wrap the clips to make them snug again.

 

[CalvinT]

My 23 is fine, did you have the issue before removal? If not, this isn't a ford issue it is a removing a one-time snap wore it. I'd say remove, inspect if all looks good then use felt or something to wrap the clips to make them snug again.

Exactly! There's nothing wrong with the cowl. I didn't do something right reinstalling it.

 

[Dan-O]

Could any of the wires you ran be interfering with the clips seating fully?

 

[userdude]

Are the clips replaceable?

 

[CalvinT]

Could any of the wires you ran be interfering with the clips seating fully?

BINGO!

It wasn't a wire, but a connector. There's a cavity on either side underneath the cowl. It gives room for a connector. I thought I had made sure the connector was in the cavity. I guess it wasn't. I should have had a clue though. A few days ago I taped a 2.5 lb weight to the cowl, thinking it would act as a damper. The noise got worse instead of better, probably because the gap under the cowl got smaller.

I took it to a touchless car wash. After the wash the noise was gone.

I think water from the car wash moved the cable/connector so there's no contact. The noise is gone.

I looked at a number of Broncos at the dealer. The cowl was tight on one. The rest were like my Bronco. So my cowl wasn't the problem. It was how I routed my wire under the cowl.

 

[Dan-O]

BINGO!

It wasn't a wire, but a connector. There's a cavity on either side underneath the cowl. It gives room for a connector. I thought I had made sure the connector was in the cavity. I guess it wasn't. I should have had a clue though. A few days ago I taped a 2.5 lb weight to the cowl, thinking it would act as a damper. The noise got worse instead of better, probably because the gap under the cowl got smaller.

I took it to a touchless car wash. After the wash the noise was gone.

I think water from the car wash moved the cable/connector so there's no contact. The noise is gone.

I looked at a number of Broncos at the dealer. The cowl was tight on one. The rest were like my Bronco. So my cowl wasn't the problem. It was how I routed my wire under the cowl.

Glad you solved the issue. Things like that drive me crazy!!

 

[CalvinT]

Glad you solved the issue. Things like that drive me crazy!!

They do me also. I can't stand rattles and squeaks. I'm a bit OCD in this area, but I don't care if anal retentive is hyphenated or not.

 

[CalvinT]

The noise is back. I took the freeway for the first time in a few weeks. Once I hit around 60-65 the noise came back.

This verifies my theory about the connector causing the problem. Fluid flow (air or water) seems to move it around. I'm going to reroute the wiring harness for my ditch lights today.

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