I've got the infamous water leak. I've had it to the dealer twice - the first time they performed the repair in the TSB plus replaced the pass. window weatherstrip (a $250 job...) and the second time they claim to have injected sealer into an area near a body seam in the area of the fuse box (no charge). I know they used a ton of that stuff because the interior smelled like paint or chemical. They also checked the cowl vents to see that they were not plugged up.

For anyone else who has had the leak in this spot (see photo), what did you do to fix it? Each time my leak has been in this very same spot. This is really getting frustrating. I tried to stick my hand above/over the plastic panel as far as my fingers would go - I could feel wires and a square of plastic around the top of the fuse box and my hand came away quite wet. More wet than what appears to be coming out the bottom on the carpet.

 

Let them repair it one more time and than lemon law it. I had the infamous leak in my 2006, had to lemon law it after 10 attempts and 40 days in service. Finally, they figured out that the robot sealing the car wasn't calibrated and it left a hole.

Quality, Ford. You don't want to mess with water, especially when it's on the fuse box. That car will never be the same. Rust, mold etc.

 

But the lemon law won't apply to a car that has 48,000 miles & 3.5 years old, will it? I never brought it in for this when it was under warranty. it is a 2007.

 

This is 2010+ section.....

 

Oh crap... I meant to post it in the 2005-09. Can one of the mods move the thread??

 

Wasn't this water leak issue fixed in 2010+ models?

 

Is it the windshield. Had that on a truck. I had a windshield put in and they didn't seal it right. It would fill my floor up.

 

Looks like you need to do the TSB procedure for sealing grommets and the pinch weld and the cowl channel seam.

Now if you can *see* it; it's worse. You need to take out the kick panel, threshold trim, shoulder harness ancor, pass seat and peel back the carpet to dry out the underpad.

Check my thread and pics.

 

Just want to point out that ssmaniac clearly stated to me in another thread that he did not lemon law it. He lives in alexandria va. and he did not meet the requiements to do so in va. In this thread he says he did.

 

My dealer has a white Mustang with half the interior ripped out trying to find a similar leak. They told me to wait till they fix that one, as mine would probably be the same. Trouble is, they've had that car in there for 4 weeks. Ford is telling them now they should remove the dash. that seems like a big job.

 

I HAVE THIS EXACT SAME ISSUE IN MY 2008. IVE BEEN DEALING WITH IT FOR QUITE SOME TIME, HERE'S WHAT I THINK IT IS.

*THERE IS A CABIN AIR FILTER THAT GOES UNDER THE COWL OF THE PASSENGER SIDE. IT HAS A HOUSING CALLED A COWL PANEL DEFLECTOR. PART # 02184A. MINE IS NON EXISTENT. WITHOUT IT, WATER FLOWS FREELY INTO THE AIR SYSTEM, OVERFLOWS AND LEAKS INTO THE PASSENGER FLOOR BOARD. YOU CAN TAKE OFF THE COWLINGS QUITE EASILY (JUST POP OUT THE PEGS, AND WIGGLE IT OUT, THEN YOU CAN SEE INSIDE THE BOX WHERE THE FILTER AND ITS FRAME (AKA THE COWL PANEL DEFLECTOR) SHOULD BE. SEE IF THEERE IS EVEN A FRAME IN THERE OR NOT. MINE WAS NOT THERE, AND ITS EASY TO SEE WITHOUT IT HOW WATER GETS IN SO FREELY. (MINE LEAKS WHEN IT RAINS)

 

HERE IS A VIDEO SHOWING EXACTLY WHAT IM TALKING ABOUT. WHEN THE GUY PULLS OUT THE FILTER WITH THE RUBBER FRAME, IF YOU DONT HAVE ONE, THERE'S YOUR PROBLEM! (IF YOU ASK ME)

 

http://youtu.be/wrTcTbUux2o

 

Yup....the rubber frame is intact on mine.

 

wiper cowl panel grometts still a concern on the 2010+ just much more infrequent
master tech at ramp motors

 

gee, you would think after all these years of the same design they would have figured out the fix at the factory level!

 

Has anyone had a water leak that went into the side wall right next to the passenger seat?

 

It seems to be inside the outside fender and the inside wall

 

Yeah, by the front floor? That's where mine is/was. See the picture in my first post. It leaked after they fixed it earlier this year, but then it didn't leak again even during the tropical storm rain this summer. I'll never understand it.