WATER LEAKS VARIOUS AREAS OF VEHICLE ELECTRICAL ACCESSORIES FUNCTIONING IMPROPERLY DUE TO WATER LEAKS LAMPS WARNING LAMPS ILLUMINATED DUE TO WATER LEAKS Article No. 98-9-13 FORD: 1997-1998 EXPEDITION, F-150, F-250 LD LINCOLN: 1998 NAVIGATOR This TSB article is being republished in its entirety 1. Remove A-pillar mouldings, rocker panel scuff to add F-150, F-250 LD, and Navigator vehicles, plates, and cowl lower scuff plates. Refer to the and to revise the text and art accordingly. appropriate Workshop Manual, Section 501-05. ISSUE Water leaks in various areas of the vehicle as identified below may be causing electrical concerns such as: Warning lamps illuminating, and/or Improper wiper operation, and/or Improper function of electrical accessories The water leaks may be caused by sealer skips, unseated grommets, and/or clogged drain tubes. ACTION Repair the water leaks. Refer to the following Service Procedures for details on: Windshield Leaks Cowl Top Leaks Cowl Side-to-Door Opening Panel Leaks Cowl Side-to-Dash Panel Leaks Moonroof Leaks 2. Apply a water hose at the bottom center of the windshield and slowly move outboard at a rate of 305mm (1 foot) per 15-20 seconds. Then move up one side, inboard along top of header to the center. Lift the moulding at top of windshield to allow water to pass through windshield moulding. NOTE A NARROW NYLON TIP ON THE END OF THE HOSE WILL ALLOW THE OPERATOR TO EASILY SLIDE THE TIP UNDER THE MOULDING AND SLOWLY MOVE IT ALONG THE INSIDE SURFACE. 3. To determine if water is entering, have an observer use a flashlight to watch for water as the hose is being moved. The observer should start looking at the dash back panel by pulling back the dash insulator pad above the water location. Grommets 4. If a leak is detected, document the location and The following procedures may include using a seam path for future reference. sealer for repairs. Recommended seam sealers are: 5. Fill any voids with pumpable Butyl Sealer. Company Part Name Phone Number NOTE 3M Ultrapro Seam Sealer (612) 733-5547 - US TO REPAIR WATER LEAKS FOUND AT THE BASE OF THE WINDSHIELD, THE LEAF SCREEN Kent Uniweld Seam Sealer (800) 654-6333 - US MUST FIRST BE REMOVED. (800) 663-2800 - Canada COWL TOP LEAKS SERVICE PROCEDURE WINDSHIELD LEAKS SERVICE PROCEDURE Refer To Figure 4 Refer To Figures 1, 2, and 3 1. Remove the leaf screen by referring to the appropriate Workshop Manual, Section 501-02. PAGE 1
Article No. 98-9-13 Cont d. 2. Spray water into cowl top-to-dash panel seam. 4. Apply seam sealer along the interface between Spray for up to 20 minutes. the cowl, dash, and floor panel. 3. Inspect the inner dash panel for water intrusion, MOONROOF LEAKS SERVICE PROCEDURE starting at the bottom of the cowl area. Refer To Figure 7 4. With the trim rocker cover and kick plate removed, pull back carpet and inspect for 1. Before beginning any diagnosis, contact the water. Webasto Tech Hotline at (800) 995-5911 Monday-Friday, 9AM-6PM EST. 5. If no water is found, look in the area of the cross car beam and/or lower windshield VIN 2. Cycle moonroof to open position. tag area. 3. Check for proper drain tube action by pouring 6. Seal inner cowl with seam sealer. approximately 1.8L (6 oz) of water into trough at each side. COWL SIDE-TO-DOOR OPENING PANEL LEAKS SERVICE PROCEDURE 4. If tubes appear to be draining properly, remove the interior A-pillar trim and sun visors. Refer to Refer To Figure 5 the appropriate Workshop Manual, Section 1. Remove the left front tire. 501-05. 5. Pull down the headliner slightly and inspect 2. Remove the inner fender splash shield from the moonroof drain tubes for kinks and/or twists. left front fender. Refer to the appropriate The drain tubes must be free from any bends Workshop Manual, Section 501-02, for details. or obstruction of water flow. 3. Remove the grille by referring to the Workshop 6. Straighten or cut drain tubes to proper length to Manual, Section 501-08. allow for free draining. 4. Remove the left front fender by referring to the Workshop Manual, Section 501-02. GROMMETS SERVICE PROCEDURE 5. Test with water. Refer To Figure 8 1. Check for missing or improperly seated 6. Apply seam sealer along the interface between grommets in the following areas: the cowl and the dash panel. This area can be reached through the access hole located near Antenna grommet on passenger side cowl the top hinge for the front door. Park brake cable grommet on driver side cowl 7. Reassemble in reverse order. Overall instrument panel grommets 8. Apply paint protection to fender bolts. COWL SIDE-TO-DASH PANEL LEAKS SERVICE PROCEDURE 2. Reseat any loose grommets or replace any missing grommets. OTHER APPLICABLE ARTICLES: NONE Refer To Figure 6 SUPERSEDES: 97-19-15 WARRANTY STATUS: Eligible Under The 1. Remove rocker cover and lower scuff panel by Provisions Of Bumper To referring to the appropriate Workshop Manual, Bumper Warranty Coverage Section 501-05. OPERATION DESCRIPTION TIME 2. 980913A Windshield Leaks Service 0.5 Hr. Inspect dash panel-to-cowl side inner sealer for Procedure skips and/or missing sealer. 980913B Additional Time If Leaf 0.4 Hr. 3. Test with water at the top of the cowl/leaf Screen Must Be Removed screen area and inspect the vehicle for water (Used With Operation A) entry. 980913C Cowl Top Leaks Service 1.3 Hrs. Procedure PAGE 2
Article No. 98-9-13 Cont d. 980913D Cowl Side-To-Door 1.9 Hrs. DEALER CODING Opening Panel Leaks CONDITION Service Procedure BASIC PART NO. CODE 980913E Cowl Side-To-Dash Panel 0.4 Hr. 18812 GROMMET(S) LEAKS 68 Leaks Service Procedure 7801610 COWL TOP LEAKS (DASH 980913F Moonroof Leaks Service 0.4 Hr. PANEL) 68 Procedure 7802012 COWL TOP LEAKS 980913G Grommets Service 0.4 Hr. (OUTER) 68 Procedure 7802018 COWL SIDE-TO-DASH PANEL LEAKS 68 7802039 COWL SIDE-TO-DOOR OPENING PANEL LEAKS 68 7803100 WINDSHIELD LEAKS 68 78502C53 MOONROOF LEAKS 68 OASIS CODES: 110000, 190000, 202000, 203000, 205000, 206000 Figure 1 - Article 98-9-13 PAGE 3
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