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Old 02-21-2014, 06:39 PM   #1
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I need help...!

This is going to take a second to explain, please bear with me...

Today it rained, and I mean it RAINED... My '09 pony was sitting in an open parking lot while I was at work. I got done at work, went out to the car and started her up and let her warm up for a minute, as I always do... Then I backed out of my parking spot, put the car in 1st and started to drive away... Suddenly there was a stream of water INSIDE my car, coming from just behind the glove box, close to the right wall... Needless to say, this shocked the crap out of me... So I parked the car and popped the hood... I couldn't see any accumulation of water... So I got back in the car and started to drive away again... MORE water came pouring out at the same spot... I didn't know what to do, so I just tried to make it home ASAP... By the time I got home, I estimate that at least 2 gallons of water had poured from somewhere into the passenger side of my car...

Can ANYONE think of any reason or explanation why this happened??? 2 days ago I had the standard single exhaust replaced with a Pypes after cat dual exhaust... But I can't imagine how this would have done anything to create my 'water problem'...

I need help...!!
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Old 02-21-2014, 06:50 PM   #2
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Did this water have a smell of radiator (antifreeze)? If so, perhaps the heater core (if your year has it in the dash area). Was the water cool to the touch? Have you had the defrost on (which would activate the air conditioner)? Then maybe the AC condensor drain tube is plugged.

Does your year have a replaceable cabin air filter? Maybe water pooled in this, and drained through the ducts.
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Old 02-21-2014, 07:35 PM   #3
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I know you have a Mustang, but I will tell you about my wife's 2002 Neon. She had this same problem and was quite common with that model. No one was ever able to find it, even the dealer. She dealt with it for years before I finally found the solution and fixed it myself. I will list a few things to look at that could cause the problem, followed by what I actually found as a solution. I don't even know if these items will apply to you car, but it is something to check out anyway.

- Do you have your HVAC set for outside air when parked while raining?

- Is the air intake cowl in front of your windshield full of debris?

- Is there a drain tube coming out of your firewall that allows the water that runs down into your cowl to drain out? Is this drain tube plugged?

- Is the weatherstripping around the cowl vents there and in good shape?

Now, after all these other things checked out, I was at my wits end. I finally found an old TSB that was no longer listed, but found it buried away where someone else had it stored. The body seam sealer from the factory where the firewall meets the inner fender well, although it looked good, must have had tiny pinholes in it. I ordered the sealer from the dealer, which in the end ended up being windshield sealer. I flooded around and over the body sealer in this area, I'm talking the top passenger corner by the firewall. I let the sealer set up. Her car has not leaked since, and I did this about a year ago. I wish I would have found that TSB sooner.

Once again, I know I'm talking about a Neon and you have a Mustang, but cars are generally put together the same way.
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Old 02-21-2014, 07:51 PM   #4
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Quote:
Originally Posted by GrabberMeBlue View Post
I know you have a Mustang, but I will tell you about my wife's 2002 Neon. She had this same problem and was quite common with that model. No one was ever able to find it, even the dealer. She dealt with it for years before I finally found the solution and fixed it myself. I will list a few things to look at that could cause the problem, followed by what I actually found as a solution. I don't even know if these items will apply to you car, but it is something to check out anyway.

- Do you have your HVAC set for outside air when parked while raining?

- Is the air intake cowl in front of your windshield full of debris?

- Is there a drain tube coming out of your firewall that allows the water that runs down into your cowl to drain out? Is this drain tube plugged?

- Is the weatherstripping around the cowl vents there and in good shape?

Now, after all these other things checked out, I was at my wits end. I finally found an old TSB that was no longer listed, but found it buried away where someone else had it stored. The body seam sealer from the factory where the firewall meets the inner fender well, although it looked good, must have had tiny pinholes in it. I ordered the sealer from the dealer, which in the end ended up being windshield sealer. I flooded around and over the body sealer in this area, I'm talking the top passenger corner by the firewall. I let the sealer set up. Her car has not leaked since, and I did this about a year ago. I wish I would have found that TSB sooner.

Once again, I know I'm talking about a Neon and you have a Mustang, but cars are generally put together the same way.


Your making your wife drive a 2002 Neon?
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Old 02-21-2014, 07:54 PM   #5
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Your making your wife drive a 2002 Neon?

She had it before we were married.
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Old 02-21-2014, 08:00 PM   #6
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She had it before we were married.

I wouldnt mind having a little Neon as a beater
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Old 02-21-2014, 10:18 PM   #7
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I also did a Google search on 2005-2009 Mustangs with rain leakage problems. Here are a few different things I found:

- Remove passenger tire and check seal between inner fender and chassis. Seal could even be missing.

- Take off the plastic cowl as if you were going to change the cabin filter, look inside for the rubber grommets in the firewall. Missing or defective.

- Foam seal between the hard black plastic weather strip retainer and the a-pillar.

- Here's a Ford TSB. Unfortunately the pictures aren't around anymore:

TSB
08-26-7
WATER LEAK - FRONT FLOOR AREA
Publication Date: December 15, 2008

FORD:2005-2009 Mustang
This article supersedes TSB 07-14-6 to update the model years, part list and service procedure.
ISSUE:

Some 2005-2009 Mustang vehicles may exhibit a difficult to diagnose water leak in the front floor area. This may be caused by loose grommets and/or sealer skips around the cowl area, loose A-pillar window weatherstrip retainer, misaligned body harness grommet through the firewall, misaligned body harness grommet from the passenger door.
ACTION:

Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE

NOTEO NOT REMOVE THE DASH OR THE DASH INSULATOR AT ANY TIME DURING THIS PROCEDURE.
Water Leak Testing Procedure

To pressurize the cabin open trunk and remove the floor carpet. Remove the plastic tail panel cover. Remove side carpet push pins and move the carpet aside. Locate the body vents in the lower rear corners of the trunk (rear of wheel wells) and tape them off. Close the trunk. Place the blower motor on high. Turn air recirculation to off mode. Close windows and doors. Open the hood and spray soapy water along body seams / grommets, particularly around the A-pillar / fender and hood hinge area, and check for bubbles.
NOTEO NOT REMOVE COWL GROMMETS DURING WATER TESTING. (FIGURE 7 AT END OF ARTICLE)

Using a garden hose equipped with a shower head attachment, or similar device, run water onto the vehicle being sure to direct water over the roof ditch moldings, side window weather strips, and windshield / cowl panel area. While water is being applied to the vehicle, have an assistant inside the vehicle verifying the location of the water intrusion.
Water Leak Inspection / Repair Procedure

Inspect the following areas for visible signs of leaks and follow the appropriate repair steps.
Verify that the plastic cowl panel grill is evenly seated against the windshield and not warped. If warped, replace with current service stock.
Remove the cowl panel grill. Refer to Workshop Manual (WSM), Section 501-02, and inspect for proper cowl panel mount grommet installation and pinch weld sealing. Water may enter the cowl channel, through the cowl panel grommets / seals or forward pinch weld, potentially causing a sloshing sound and/or water leaking down the dash kick panel area. If there is standing water in the cowl channel, remove by siphoning through a cowl panel mount grommet hole. (Figures 7-8 - end of article)
Verify that the ten (10) cowl panel mount grommets and seals are installed and sealing tightly to the vehicle. If any are missing, or the seals are damaged, replace as necessary. (Figure 1)


Figure 1 - Article 08-26-7

Remove old cowl grommets and clean entire cowl surface with a suitable wax and grease remover. If silicone and/or seam sealer was used to seal grommets, ensure all sealer is removed before installing new grommets.
With surface clean and prepped, snap the hot melt cowl grommet into cowl panel.
Using a suitable heat gun, heat the hot melt cowl grommet until the hot melt material begins to squeeze out from under the plastic grommet. Do not over heat the grommet because deformation of the plastic grommet may occur.
After heating the grommets, a light amount of pressure may be applied to the outer perimeter of the grommet to help sealing.
Do not over heat around windshield or fender edges or damage may result.
NOTE:HEAT SEALED GROMMETS WERE USED IN PRODUCTION STARTING WITH VEHICLES BUILT ON 9/4/2008.

Inspect the cowl panel to bulk head pinch weld and A-Post to cowl joint for any skips in seam sealer or excessive gaps between panels.
To ensure a water tight seal, apply a small amount of Motorcraft Seam Sealer to the pinch weld and work into seam with fingertip, leaving a small amount on the edge, especially near the windshield center bracket area. (Figure 2)


Figure 2 - Article 08-26-7

NOTEO NOT USE SILICONE.

Check the main body wiring harness grommet for proper seating into the bulkhead on the driver / passenger side.
Position the grommet into the bulkhead making sure the grommet is fully seated and sealed. If there is any aftermarket wiring installed through the grommet, reroute and seal as necessary. To ensure proper sealing around the wiring harness grommet, apply a small amount of Motorcraft Seam Sealer and install the grommet. (Figure 3)


Figure 3 - Article 08-26-7

Verify that the door to the A-pillar wiring harness grommet is fully seated into the A-pillar.
To ensure proper sealing around the wiring harness grommet, apply a small amount of Motorcraft Seam Sealer and install the grommet into the A-pillar. (Figure 4)


Figure 4 - Article 08-26-7

Remove and inspect the foam seal of window weatherstrip retainer at the A-pillar. Tears in the foam seal may allow water to enter the vehicle, between window weatherstrip retainer and the A-Pillar, and travel inside the interior A-Pillar trim molding into the dash kick panel area. (Figure 5)


Figure 5 - Article 08-26-7

Replace window weatherstrip retainer, if foam seal is damaged. (Figure 6)


Figure 6 - Article 08-26-7

Assemble other trim as required.
If no leaks are found in these areas, refer to WSM, Section 501-00 for water leak diagnostics.

PART NUMBERPART NAME
9R3Z-63517C58-ARetainer-Cowl Panel
9R3Z-6351238-ARetainer-Weather Right Side
9R3Z-6351239-ARetainer-weather Left Side
TA-2Motorcraft Seam Seal
WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATIONDESCRIPTIONTIME
MT082607Use SLTS Operations If Available; Claim Additional Diagnosis Or Labor Performed As Actual TimeActual Time
DEALER CODING

BASIC PART NO.CONDITION CODE
63517c5807



Figure 7 - Article 08-26-7




Figure 8 - Article 08-26-7

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
Copyright © 2008 Ford Motor Company
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Old 02-22-2014, 01:55 AM   #8
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So much information... I'm not mechanically inclined, and don't understand most of what you sent, but I truly appreciate the effort... I hope 'the guys' at the dealership can fix this... If this was a problem wide spread enough to be written about, why didn't Ford do a recall...? Again, thank you GrabberMeBlue
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Old 02-22-2014, 09:16 AM   #9
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So much information... I'm not mechanically inclined, and don't understand most of what you sent, but I truly appreciate the effort... I hope 'the guys' at the dealership can fix this... If this was a problem wide spread enough to be written about, why didn't Ford do a recall...? Again, thank you GrabberMeBlue

I don't think you need to be mechanically inclined to check most of these things out, if not all. Maybe you have a friend or family member you can show this thread to and they can help you out. You would be surprised what you can learn just by digging in. It won't be free at the dealer, and they might not get it fixed either.
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Old 02-22-2014, 10:59 AM   #10
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Dealer won't do anything I had the exact same thing look on the firewall for a black rubber piece it connects to the cowl by the wiper blades over time they plug up from leaves and debris and the water flows back inside the car on the passenger side from behind the glove box it will be easy to find it looks like a flattened black hose lol I took it to the dealer and they had no idea I started checkin under the hood and finally found that lol it freaked me out when it happened to mine
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Old 02-24-2014, 03:30 PM   #11
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Originally Posted by GrabberMeBlue View Post
I don't think you need to be mechanically inclined to check most of these things out, if not all. Maybe you have a friend or family member you can show this thread to and they can help you out. You would be surprised what you can learn just by digging in. It won't be free at the dealer, and they might not get it fixed either.
I had the same problem with my car and the dealer had it fixed up just fine. Its been over a year and no problems with the leak again. It mightve been around $100. Hopefully his has already been fixed by now though but just in case it hasn't or someone else has the same problem thought i'd add on.
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Old 03-06-2014, 05:15 AM   #12
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My '06 pony package had the same problem. It was only when I left my car out and it rained really hard. If it was under car port it didn't do it and if I parked with the front end lower than the back end (when parking on a hill) it wouldn't do it either.. It only did this 3 or 4 times in about 1 1/2 month period. Been close to 6 months now and it haven't seen any water run out. Puzzled me, I couldn't find anywhere the water could be coming from. I'm decently knowledgeable about cars and mechanically inclined but this stomped me. No complaints though since it magically stopped.
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Old 03-06-2014, 07:29 AM   #13
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Any updates from the OP whether they got theirs fixed or not?
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