WATER LEAKS - REMOVABLE ROOF AND CONVERTIBLE TOP - … · 5. Run normally pressurized tap water...

WATER LEAKS - REMOVABLE ROOF AND CONVERTIBLE TOP - SERVICE TIPS

TECHNICAL SERVICE BULLETIN

Reference Number(s): 04-9-5, Date of Issue: May 17, 2004

FORD: 2002-2005 THUNDERBIRD

Superceded Bulletin(s): 02-21-14, Date of Issue: October 28, 2002

DESCRIPTION

BODY - WATER LEAKS - REMOVABLE ROOF AND CONVERTIBLE TOP - SERVICE TIPS

NOTE: This article supersedes TSB 02-21-14 to update the model years and

service procedure.

ISSUE

Some 2002-2005 Thunderbird vehicles may exhibit water leaks with the removable roof installed

or convertible top in the raised position.

ACTION

This article will address the most common areas of water leaks associated with the removable

roof and convertible top and will assist in making an effective repair. Refer to the following service

tips.

SERVICE PROCEDURE

NOTE: THUNDERBIRD ROOF SEALING SYSTEMS ARE DESIGNED TO

PREVENT WATER FROM ENTERING THE VEHICLE DURING NORMAL EVENTS OF

RAIN. WATER INGRESS RESULTING FROM EXPOSURE TO A HIGH PRESSURE

WASHER (POWER WASHER) OR AUTOMATED CAR WASH THAT USES HIGH

PRESSURE WASHING EQUIPMENT SHOULD BE CONSIDERED NORMAL.

NOTE: A REMOVABLE ROOF STORAGE CART MUST BE AVAILABLE TO

PERFORM THE SERVICE PROCEDURES IN THIS ARTICLE.

REMOVABLE ROOF AND REMOVABLE ROOF WEATHERSTRIP PRELIMINARY POSITION

CHECK

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NOTE: ONLY WEATHERSTRIPS THAT ARE PHYSICALLY DAMAGED SHOULD

BE REPLACED. MOST WATER LEAKS CAN BE REPAIRED BY ADJUSTMENT

PROCEDURES OUTLINED IN THIS ARTICLE.

1. Check that all weatherstrips are positioned correctly on the removable roof, vehicle

header and a-pillar (Fig 1 and Fig 2 ).

Fig 1: Removable Roof A-Pillar Weatherstrip Position



Fig 2: Roof Weatherstrip Position In Door Opening

2. Check for the proper 7 mm gap at each a-pillar corner between the chrome windshield

header molding and the removable roof (Fig 3 ).



Fig 3: 7 mm Gap At A-Pillar Corner

a. If the gap between the chrome windshield header molding and removable roof

is correct then proceed to the service procedure section that refers to the leak

location on vehicle.

b. If the gap is not correct then proceed to Step 3.

3. Remove the removable roof.

4. Remove the two (2) trim covers at the b-pillar area to access the two (2) removable roof

top locator brackets (Workshop Manual Section 501-00).

5. Scribe each removable roof locator bracket position for reference (Fig 4 ).



Fig 4: Removable Roof Locator Bracket Position

6. Loosen the removable roof locator bracket 10 mm bolts (two (2) per bracket) and adjust

the locator brackets forward or rearward as necessary to obtain the proper 7 mm gap

between the chrome windshield header molding and the removable roof (Fig 3 and Fig

4 ).

7. It may also be necessary to adjust the front location tab/block on the removable roof by

loosening the three (3) Torx bolts on each block (Fig 5 ).



Fig 5: Front Location Tab/Block On Removable Roof

8. Reinstall the removable roof and recheck for the proper 7 mm gap between the chrome

windshield header molding and the removable roof (Fig 3 ). Repeat Steps 4-7 until gap

is correct.

9. Water test vehicle using only normally pressurized tap water from a standard sized

garden hose.

a. If leak is no longer present return the vehicle to the customer.

b. If leak is still present proceed to the section of the service procedure that

refers to the leak location on vehicle.



REMOVABLE ROOF WATER LEAKS AT A-PILLAR (FRONT UPPER CORNER OF DOOR

GLASS)

1. Verify the water leak condition. For testing, use only normally pressurized tap water from

a standard size garden hose.

2. Reset the power window short drop function. Refer to the Owner's Guide.

3. Retest for water leak.

a. If leak is no longer present return the vehicle to the customer.

b. If leak is still present then proceed to Step 4.

4. Remove the removable roof and check that the weatherstrip corners at the top of the

a-pillars near the windshield weatherstrips are seated/positioned correctly (Fig 6 ).

Fig 6: Weatherstrip Corner At Top Of A-Pillar

a. If gaps are present, correct by pushing/repositioning weatherstrip as needed.

Reinstall the roof and water test. If the leak is corrected return vehicle to

customer.



b. If weatherstrips were seated correctly, proceed to Step 5.

5. Water, which enters the vehicle between the side weatherstrip and the door glass near

the top of the a-pillar, can be repaired by adding seal stuffer, part number 2W6Z-

76025B52-AA. The part package contains 2 stuffers. Install one stuffer on each side of

the vehicle following Steps 5-9.

NOTE: SOME VEHICLES MAY ALREADY HAVE THE SEAL STUFFER

INSTALLED. IF SEAL STUFFER IS ALREADY INSTALLED VERIFY THAT IT

HAS BEEN POSITIONED CORRECTLY PER STEP 9. IF SEAL STUFFER IS

NOT POSITIONED CORRECTLY REMOVE AND REPLACE WITH A NEW

SEAL STUFFER FOLLOWING STEPS 5-9.

6. Remove the roof from the vehicle and place in the removable roof storage cart.

7. Dry all moisture and clean all dirt and debris from the weatherstrips on the roof.

8. Apply 3-4 small evenly placed dabs of Ford Trim and Weatherstrip Adhesive, part

number TA-14, to one side of the seal stuffer. Do not coat the entire stuffer with

adhesive.

9. Position the seal stuffer behind the secondary seal approximately 20 mm rearward from

the front edge of the seal. For best results have an assistant open the weatherstrip so

proper placement can be obtained (Fig 7 ) (the primary weatherstrip has been removed

in the figure for clarity).



Fig 7: Positioning Seal Stuffer Behind Secondary Seal

10. Install the roof and water test to verify the repair.

11. If water leak continues in the same location, the weatherstrips may require adjustment

or the door glass may not be fully rolling up into the weatherstrip, Proceed to

REMOVABLE ROOF LEAKS AROUND DOOR GLASS WEATHERSTRIPS.

REMOVABLE ROOF LEAKS AROUND DOOR GLASS WEATHERSTRIPS

Adjusting or repositioning the weatherstrips may repair water, which enters the vehicle between

the side weatherstrips and the door glass.



1. First, reset the power window short drop function. Refer to the Owner's Guide. Verify

that the weatherstrips along the glass are uniformly pressing against the door glass.

This can be done by moistening the weatherstrips with water and closing the door. The

wet weatherstrips will clearly show their contact pattern against the glass.

2. Where no contact pattern is present, firmly grasp and pull the weatherstrip to the desired

location to achieve a uniform seal against the glass. The weatherstrip is attached to

metal flanges on the roof, which will bend slightly.

a. If leak condition is corrected return vehicle to customer.

b. If adjustments do not correct the condition, the door glass may not be fully

rolling up into the weatherstrip, proceed to Step 3.

3. Make certain the windows are capable of completely seating into the weatherstrip.

a. Open the door and manually trip the door latch closed. This will raise the glass

with the short drop function.

b. Measure the distance between the peaked edge on the rear of the door glass

to the top of the belt molding seal. If greater than 9.5 mm (3/8"), the glass is

not rolling up fully into the weatherstrips, proceed to Step 4. If 9.5 mm (3/8") or

less, the glass is lifting properly. Verify weatherstrips are still positioned

correctly (Fig 8 ).



Fig 8: Measuring Between Door Glass & Belt Molding Seal

4. The glass may not mechanically roll up far enough to seal.

a. Keep door open, and the window in the raised position from the short drop

feature.

b. Remove the door trim panel to access the rear glass adjustment nut. Refer to

Workshop Manual, Section 501-05.

c. Loosen the rear 10 mm regulator clamp bolt and pull upward on the glass until

a maximum of 9.5 mm (3/8") can be measured between the peaked edge on

the rear edge of the door glass and the top of the belt molding seal (Fig 8 ).



d. Torque the bolt to 12 N.m (9 lb-ft).

e. Assemble the door trim panel; flip the latch closed to drop the glass, and water

test.

f. If water leaks are corrected, return vehicle to customer.

g. If water leak continues, verify weatherstrips are still positioned correctly then

inspect and replace any damaged weatherstrips as necessary.

REMOVABLE ROOF WATER LEAKS ALONG WINDSHIELD HEADER

1. Verify the two (2) roof T40 a-pillar attaching screws are torqued to 9 N.m (80 lb-in) and

that latch handles below the porthole windows are fully engaged.

2. If fasteners are found loose or latches were not engaged, tighten/latch then water test.

a. If leak is repaired, return vehicle to customer.

b. If leaking continues proceed to Step 3.

3. Isolate source of leak by first applying masking tape over the windshield header seal.

The masking tape should overlap onto the chrome windshield header molding and onto

the roof header trim bead (Fig 9 ).

Fig 9: Windshield Header Molding And Seal



4. Remove the interior header trim panel from the removable roof by grasping and firmly

pulling down the panel. This will aid in locating the source area of the water leak.

5. Run normally pressurized tap water from a standard size garden hose over the taped off

area.

a. If the leak is no longer present proceed to Step 6.

b. If the leak is still present proceed to Step 12.

6. Remove the removable roof.

7. Inspect windshield header seal for damage.

a. If seal is damaged repair as necessary and perform water test. Return vehicle

to customer if leak has been repaired.

b. If seal is OK then proceed to Step 8.

8. Remove the chrome windshield header molding and the left and right chrome a-pillar

moldings and inspect seams in windshield frame (refer to Workshop Manual Section

501-00 for removal instructions).

9. Seal seams as necessary with Silicone Gasket and Sealant, part number TA-30.

10. Reinstall chrome windshield header molding and the left and right chrome a-pillar

moldings.

11. Reinstall the removable roof and verify the repair.

a. If leak is still present proceed to Step 12.

b. If leak is no longer present return vehicle to customer.

12. Apply masking tape over removable roof to roof header trim bead seam and over

removable roof to drip rail molding seam (Fig 10 ).



Fig 10: Removable Roof To Roof Header Trim Bead Seam

13. Run normally pressurized tap water from a standard size garden hose over the taped off

area.

14. If water is not entering the vehicle during this test, it may be penetrating between the

removable roof and roof header trim bead or between the removable roof and the

removable roof drip rail molding.

15. Remove the roof and carefully set on the removable roof storage cart.

16. Check that the weatherstrip corners at the top of the a-pillars near the windshield header

weatherstrips are seated correctly (Fig 11 ).




a. If gaps are present, correct by pushing/repositioning the weatherstrip as

needed. Reinstall roof and water test. If leak is corrected return vehicle to

customer.

b. If weatherstrips were seated correctly, proceed to Step 17.

17. On the side where the roof leak is present (RF or LF corner), loosen screws on the

underside of roof that attach the roof header trim bead (Fig 12 ).



Fig 12: Roof Header Trim Bead On Underside Of Roof

18. Starting on the top side of removable roof, apply a small bead of clear silicone rubber,

part number TA-32, between the roof header trim bead and the removable roof starting

in the corner where the leak is inward about 20.5 cm (8") toward the center of the roof.

(Fig 13 ).



Fig 13: Silicone Application To Roof Header Trim Bead Seam

NOTE: USE A SOFT FLEXIBLE PLASTIC OR RUBBER PADDLE (SUCH

AS A BODY FILLER SPREADER) TO GENTLY LIFT UP ON TRIM MOLDING

WHILE APPLYING THE SEALANT BEAD.

CAUTION: DO NOT USE TOOLS TO DIRECT THE SILICONE THAT

WILL DAMAGE THE PAINT. TEST TOOL ON A SCRAP PIECE OF PAINTED

SHEET METAL FIRST TO CHECK FOR EVIDENCE OF PAINT DAMAGE.



19. Immediately clean the excess silicone from the roof with a damp cloth.

20. Repeat application of clear silicone rubber, part number TA-32, between the drip rail

molding and removable roof starting in the corner where the leak is back to about the

point where side window starts to curve down at b-pillar (Fig 13 ).

21. Immediately clean the excess silicone from the roof with a damp cloth.

22. Working on the underside of the removable roof, apply a small bead of clear silicone

rubber, part number TA-32, between the roof header trim bead and the removable roof

(Fig 12 ).

23. Retighten the roof header trim bead screws that were loosened in Step 17 of this

procedure (Fig 12 ).

24. Secure rubber flap down on underside corner where leak is of removable roof with Ford

Trim and Weatherstrip Adhesive TA-14 (Fig 12 ).

25. Reinstall the removable roof and reset the power window short drop function. Refer to

the Owner's Guide.

NOTE: MAKE SURE THAT THE REMOVABLE ROOF HAS THE PROPER

7 MM GAP BETWEEN THE CHROME WINDSHIELD HEADER MOLDING

AND THE REMOVABLE ROOF (Fig 14 ).

Fig 14: 7 mm Gap At A-Pillar Corner



26. Water test with normally pressurized tap water through a standard size garden hose to

verify the repair.

CONVERTIBLE TOP WATER LEAKS AROUND DOOR GLASS

1. Verify the water leak. Direct normally pressurized tap water from a standard size garden

hose around the effected door glass.

2. Reset the power window short drop function. Refer to the Owner's Guide for additional

information.

3. Retest for water leak.

a. If water leak has been resolved return vehicle to customer.

b. If water leak is still present then proceed to Step 4.

4. Check that the weatherstrips up the a-pillar, at the corner of the a-pillar and windshield,

and along the convertible top that seals the door glass are not damaged and are

positioned correctly. Adjust/reposition weatherstrips as needed and water test (Fig 15

-Fig 18 ).


b. If leak is not corrected proceed to Step 5.



Fig 15: Convertible Top Weatherstrip Inside A-Pillar



Fig 16: Gap Between First & Second Convertible Top Weatherstrip



Fig 17: Gap Between Second & Third Convertible Top Weatherstrip



Fig 18: Third Convertible Top Weatherstrip At Door Opening Weatherstrip

NOTE: ONLY WEATHERSTRIPS THAT ARE PHYSICALLY DAMAGED

SHOULD BE REPLACED. FOLLOWING THE STEPS IN THIS ARTICLE THAT

PROVIDE ADJUSTMENT DETAILS CAN REPAIR MOST WATER LEAKS.

5. Roll down the windows and operate the convertible top down and back up. Once the top

is at the windshield header and the pump motor begins to "stall", keep the button

depressed for 2-3 seconds additional before latching the top. If the top is not completely

positioned up, the top frame and weatherstrips will not be positioned correctly. Roll the

windows up and water test.





6. Check for excessive gaps between the weatherstrips on the convertible top. Adjust the

position of the weatherstrips on their mounting flange, or bend the mounting flange as

needed to correct (Fig 15 -Fig 18 ).



7. Lower the convertible top and check that the weatherstrip corners at the top of the

a-pillars near the windshield header weatherstrips are seated/positioned correctly (Fig

19 ).


a. If gaps are present, correct by pushing/repositioning the weatherstrip as

needed. Raise the roof and water test. If leak condition is corrected return

vehicle to customer.

b. If weatherstrips were seated correctly proceed to Step 8.

8. Make certain the windows are capable of completely seating into the weatherstrip.



a. Raise the roof. Open the door and manually trip the door latch closed. This will

raise the glass with the short drop function.

b. Measure the distance between the peaked edge on the rear of the door glass

to the top of the belt molding seal. If greater than 9.5 mm (3/8"), the glass is

not rolling up fully into the weatherstrips, proceed to Step 12. If 9.5 mm (3/8")

or less, proceed to Step 9 (Fig 20 ).

Fig 20: Measuring Between Door Glass & Belt Molding Seal

9. Lift the outside door handle and trip the door latch open, which will drop the door glass.

Close the affected door and measure and record the distance between the silkscreen on

the door glass and the top of the belt molding seal. The measurement distance is not

critical. The rule in the figure is for reference (Fig 21 ).



Fig 21: Measuring Between Silkscreen & Belt Molding Seal

10. Open the affected door. Exert light hand pressure against the outside of the glass. Shut

the door with normal force and keep pressure on the glass until the short-drop function

raises the glass into the weatherstrip. Again measure between the silkscreen and the

top of the belt molding seal (Fig 21 ).

11. If measurement is now greater than observed in Step 8, proceed to Step 13. If

measurement stayed the same, proceed to Step 12.

12. The glass may not mechanically be able to roll up far enough to seal.

a. Raise the roof. Open the affected door and command the system to roll the

glass up with the short-drop feature. This is done by manually tripping the door

latch.

b. Remove the door trim panel to access the rear glass adjustment nut. Refer to

Workshop Manual, Section 501-05.

c. Loosen the rear 10 mm regulator clamp bolt and pull upward on the glass until

a maximum of 9.5 mm (3/8") can be measured between the peaked edge on

the rear of the door glass to the top of the belt molding seal.



d. Torque the bolt to 12 N.m (9 lb-ft).

e. Assemble the door trim panel; flip the door latch open to drop the glass and

water test.

f. If leak condition is corrected return vehicle to customer.

g. If leak is not corrected proceed to Step 13.

13. The window motor may be stalling before the glass can properly seal. Strike "down and

in" along the stitch bead on the edge of the convertible top, starting from the a-pillar area

back approximately 50 cm (20") with a rubber mallet. This area is where the top of the

glass penetrates a U-shaped channel in the weatherstrip. If the weatherstrip flange on

the convertible top is not rolled inboard enough, the door glass will not properly enter the

weatherstrip (Fig 22 ).

Fig 22: Reshaping Weatherstrip Flange With Mallet

14. After the adjustment in Step 13 is made, normally open and close the door checking that

the glass is rolling all the way up into the weatherstrip then water test.



15. If the glass is still not fully entering the weatherstrips, adjust the channel in the rear

portion of the second weatherstrip "up" to allow closure. This area of the weatherstrip is



where it transitions from the channel along the roof to a compression seal along where

the b-pillar would be present. Use the handle of a rubber mallet to bend the weatherstrip

and convertible top flange "up" then water test (Fig 23 ).



Fig 23: Weatherstrip Transition From Roof To B-Pillar

16. Check that the weatherstrips are uniformly pressing against the door glass. This can be

done by moistening the weatherstrips with water and closing the door. The wet

weatherstrips will clearly show their contact pattern against the glass. This is critical

along the rearward slope of the glass (b-pillar).

17. The weatherstrips are positioned on metal mounting flanges that are part of the

convertible top frame. These flanges may be bent slightly to improve the weatherstrip

pattern. To adjust, simply grasp the weatherstrip and move it inboard or outboard to

improve contact against the glass.

PARTS INFORMATION

PARTS INFORMATION

Part Number Part Name

TA-14 Weatherstrip Adhesive



TA-30 Silicone Sealant

TA-32 Clear Silicone Rubber

2W6Z-76025B52-AA Hard Top Seal Stuffer

WARRANTY INFORMATION

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.



WATER LEAKS - REMOVABLE ROOF AND CONVERTIBLE TOP - … · 5. Run normally pressurized tap water...

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