Body - Trunk/Liftgate Area Water Leaks
Article No.02-15-6
08/05/02
WATER LEAKS - WATER LEAK FROM
TRUNK/LIFTGATE AREA - SERVICE TIPS
FORD:
2000-2003 FOCUS
ISSUE
Some vehicles may exhibit a difficult to diagnose or difficult to repair water leak condition in the trunk/Liftgate area. This may be caused by panel sealing, panel adjustments, weatherstrips, etc.
ACTION
Some common water leak locations and repair recommendations are listed below to help reduce repair time and increase repair effectiveness.
SERVICE PROCEDURE
1. IF WATER IS FOUND ON SEDAN TRUNK CARPET NEAR LEFT/RIGHT CORNERS.
Potential Leak Sources:
a. Pin holes in decklid drain trough sealer.
Refer to Figures 1 and 2.
^ Locate pin holes in the sealer on the drain trough (check both top and underside of drain trough joint for leaks)
^ Caulk in area of missing sealer using silicone-based caulk
b. Backglass sealed improperly.
^ Reseal backglass as necessary
2. IF WATER IS FOUND ON SEDAN TRUNK CARPET NEAR MIDDLE.
Potential Leak Source:
a. Decklid package tray sheet metal flange too low (weatherstrip not sealed against decklid). Refer to Figure 3.
^ Perform chalk test along package tray flange area to confirm areas of lost contact with weatherstrip
^ Move the flange upwards in areas where low
^ Perform chalk test again to verify contact with weatherstrip
b. Backglass sealed improperly.
^ Reseal backglass as necessary
3. IF WATER IS FOUND ON SEDAN PLASTIC TRIM AROUND DECKLID STRIKER.
Potential Leak Sources:
a. Missing decklid lock grommet.
^ Replace missing lock grommet
b. High decklid fit relative to quarter panel.
^ Perform chalk test to confirm areas of lost contact with weatherstrip
^ Adjust decklid striker downward/forward as necessary to correct fit
^ Perform chalk test again to verify contact with weatherstrip
c. Center high mount brake lamp not sealed (CHMSL).
^ Verify seal around CHMSL is not damaged and is fully seated against seal surface
^ Fully seat or replace CHMSL as necessary
4. IF WATER IS FOUND ON SEDAN CARPET TRIM COVERING DECKLID LATCH REINFORCEMENT.
Potential Leak Sources:
a. Missing decklid lock grommet.
^ Replace missing lock grommet
b. Center high mount brake lamp not sealed (CHMSL).
^ Verify seal around CHMSL is not damaged and is fully seated against seal surface
^ Fully seat or replace CHMSL as necessary
5. IF WATER IS FOUND IN SEDAN SPARE TIRE WELL.
Potential Leak Sources:
a. Weatherstrip not crimped to sheet metal flange (loose or gapping) Refer to Figure 4.
^ Check if loose by pulling on weatherstrip bulb lightly (it should be tight to sheet metal flange)
^ Visually inspect weatherstrip for gaps between weatherstrip carrier and sheet metal flange
^ Reseat/re-crimp weatherstrip to flange
b. Damaged weatherstrip.
^ Visually inspect weatherstrip bulb in area of leak for tears
^ Replace weatherstrip
6. IF WATER IS FOUND ON WAGON REAR HEADLINER.
Potential Leak Source:
a. Wiring harness grommet not seated/loose Refer to Figure 5.
^ Pull on both ends (body-side and liftgate-side) of wiring harness to check retention of grommet to sheet metal
^ If grommets are loose, snap into place
7. IF WATER IS FOUND ON WAGON CARGO AREA CARPET.
Potential Leak Sources:
a. Center high mount brake lamp not sealed (CHMSL).
^ Verify seal around CHMSL is not damaged and is fully seated against seal surface
^ Fully seat or replace CHMSL as necessary
b. Top sheet metal flange too low. Refer to Figure 6.
^ Perform chalk test along top flange area to confirm areas of lost contact with weatherstrip
^ Move flange upwards in areas where low
^ Perform chalk test again to verify contact with weatherstrip
c. Damaged weatherstrip.
^ Visually inspect weatherstrip bulb in area of leak for tears
^ Replace weatherstrip
d. Liftgate fit (striker too far rearward).
^ Perform chalk test to confirm areas of lost contact with weatherstrip
^ Adjust the liftgate striker
^ Perform chalk test again to verify contact with weatherstrip
e. Backglass sealed improperly.
^ Reseal backglass as necessary
8. IF WATER IS FOUND ON WAGON PLASTIC TRIM AROUND LIFTGATE STRIKER.
Potential Leak Sources:
a. Wiring harness grommet not seated/loose.
Refer To Figure 5.
^ Pull on both ends (body-side and liftgate-side) of wiring harness to check retention of grommet to sheet metal
^ If grommets are loose, snap into place
b. Left/right sheet metal flanges inboard.
Refer to Figure 7.
^ Perform chalk test along flange area to confirm areas of lost contact between weatherstrip and liftgate
^ Move flange outward in areas where inboard
^ Perform chalk test again to verify contact with weatherstrip
C. Top corner sheet metal flange height mismatches (at joints).
^ Remove weatherstrip in suspected area of leak
^ If observe step-joint (area where two sheet metal flanges come together) with height mismatches greater than 1/4" (6 mm), grind sheet metal flanges to eliminate step-joint
^ Prime/paint areas where grinding occurred Reinstall weatherstrip on flange
d. Excessive sealer between sheet metal flange joints at bottom corners (weatherstrip leaks).
^ Remove weatherstrip in suspected area of leak
^ If observe excessive sealer on sheet metal flanges, remove sealer expulsion Prime/paint areas where sealer removed if necessary
^ Reinstall weatherstrip on flange
e. Liftgate fit (striker too far rearward).
^ Perform chalk test to confirm areas of lost contact with weatherstrip
^ Adjust the liftgate striker Perform chalk test again to verify contact with weatherstrip
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 110000, 111000