Sunroof leak, not the tubes?

[R_Lefebvre]

Ok, I bought this 04 SE a few months ago, and while installing radio stuff, I found the carpet was soaked and the floor is rusty.

I went to the LR dealership as I still had a bit of warranty left. They said that they repositioned the sunroof drain tubes and resealed them. I'm not really sure what they mean by that. I could smell a solvent smell in the car, so they must have done something.

However, they also said I will have a remaining leak due to a crappy aftermarket windshield install that was not their responsibility.

I have proceeded to pull the car apart to fix this problem.

-I've got the carpets out so that they can dry and I can put some rust paint on the floor. I've also removed most of the interior trim.

-During a recent rain storm, the floor actually collected a little puddle of water. I can see it running down the metal behind where the kickpanel/deadpedal trim used to be. The headliner got wet on the front corners. Sometimes when turning a corner, water dripped out of the sunroof switch area.

So, I've established that after the LR repair to the drains, something is still happening.

-I've taken off the A pillar trim on the inside and outside so I can track down the problem.

-The windshield install does indeed look like a crappy install, however, I can't see how water could get past the TONS of goop they've got on there.

-I soaked the truck, starting from the top and working my way up. I used free flow from a hose, and sprayer, all around the windshield, and NOTHING came into the truck! I did the seals on the sides, the cowl area, the top, the sunroof, nothing came into the truck and pooled on the floor.

-I checked the drain tubes as best I could. I poured water from a jug into the sunroof tray. It gushed out the bottom of the truck as it should. Nothing came inside the truck. The drains seem to run free.

-I went to move the truck, and then water poured out of the upper trim/sunroof switch/rear view mirror area!

How in the heck is water collecting up there?

[Disco Mike]

You should have taken it back to the dealer since they were the last to work on it while in warranty.
If they in fact mis diagnosed the problem it is still there to redue under another warranty work order reflecting back to the last attempt to fix it.
Mike

[R_Lefebvre]

I would have, but I really have no confidence in them. They're pathetic.

I'm going to drive 3 hours there and back to drop the truck off, then 3 hours to pick it up again. Burning like $200 in fuel, and I have no confidence they'll even fix it. It was a waste of time taking there in the first place, since I actually had to go twice, making 4 trips.... and apparently they haven't even fixed it.

What a friggen joke. If I was wealthy enough to buy a new Rover, I'd never buy one because I'm not going to drop that kind of coin on a company that puts people through that!

Anyway... </rant>

Is it the case that if the water is getting into that trim, it can't be coming from the windshield can it? Water doesn't run uphill. Must be coming from the sunroof still. I'll have a look... if this involves buying new parts, I will go back if I think I can prove the case to them. Only thing is, I just know they're going to say:

"Oh well, we can't cover this, you've dismantled the vehicle, how do we know you didn't cause this!"

[HeadlinerExpress]

Based on what all you have done, removed interior trim, water tested. It possible the sunroof exterior trim plate may not be sealed between the body of the truck and the plastic trim plate.

Herein Florida we have an issue with the exterior plastic trim in which the glass lays in warps with age and won’t allow the glass to lay flush on the seal and water comes in. or your roof won’t close or open.

Not a sunroof seal issue, the plastic outer sunroof tray warps, perhaps this might be something to consider if water was getting in behind the back of the sunroof between the body and the seal water could come in and go just about anywhere.

Another thought might be to totally remove the front drain tubes and make sure they have not been cut short; we have experienced drain tubes cut in half hidden behind the front "A" post after body shops have done repairs.

*** My best guess is not the drain tubes or windshield; if this is a Sunroof problem I think your problem is where the drain tubes connect to the front of the Sunroof at the lower tub assembly. There is a separate plastic tray that has a small amount of silicone on them that is used to attach them to the lower tub assembly (metal). This is where the Drain Tube is attached.

We have had many of these brake over the years the hard black plastic tube that comes out of the lower tub brakes off inside the clear or yellowed from age sunroof drain tube. Water then drops on the Headliner Board in the front near the sunroof switch

(Series I & II only have 2 drain tubes both located on the front of the sunroof) unlike a range rover has 4 drain tubes. This could be the answer you’re looking for.

[Steph]

You most likely have done this already, but I had similar problem where a few drops would be coming in, even though the drains were found to work the way they should.

I found that the seal on which the sunroof glass lays, was dirty enough to let the water that was waiting to be evacuated by the drains come in. I used silicone spray and cleaned the seal and inner glass and problem was solved.

[Petewhit]

Suffered this on a 1999 td5 and a friends 2001 td5
Cure... remove all interior headlining. sounds difficult but isn't. take your time!
Reseal sunroof mount to metal of the roof. Use a flexible mastik, something like a caravan sealant. Do not use silicon sealant for a bath!
Unexpected showers solved. Tell tale signs were water from behind the front interior light and a wet rear carpet.
Hope this helps.