Body - Moonroof Water Leaks
TSB 04-15-908/09/04
MOONROOF WATER LEAKS
FORD:
2003-2004 Expedition
LINCOLN:
2003-2004 Navigator
ISSUE
Some 2003-2004 Expedition/Navigator vehicles equipped with a moonroof may exhibit water leaks. The leaks occur at either the left or right A-pillar grab handle, at the headliner along the moonroof trim, or near the DVD player (if equipped). The condition may be due to a loose or disconnected moonroof drain tube, improperly routed drain tube, or a blocked drain tube.
ACTION
To service, inspect moonroof drain tube connections, check for blockages or restrictions at the front or rear drain tubes and repair as necessary. Refer to the following service procedure.
SERVICE PROCEDURE
1. Check for disconnected front drain tubes by pouring clean water into front moonroof drain holes (Figure 1). If tubes are disconnected the water will drip from A-pillar grab handles.
a. If the tube is found disconnected, remove the headliner and reconnect the drain tubes. Refer to Workshop Manual Section 501-05. Verify the leak is corrected. Reassemble in reverse order.
b. If the tube is found to be cracked, proceed to FRONT MOONROOF DRAIN TUBE CHECK AND REPLACEMENT.
c. If tube is connected and not cracked, proceed to Step 3.
2. Check for disconnected rear drain tubes by opening rear doors, pulling down door weather strip, open up the headliner above the door opening and using a flashlight visually check for connected drain tubes (Figure 2).
a. If tube is found disconnected remove the headliner and reconnect the drain tube. Refer to Workshop Manual Section 501-05. Verify the leak is corrected. Reassemble in reverse order.
b. If the tube is cracked proceed to REAR MOONROOF DRAIN TUBE CHECK AND REPLACEMENT.
c. If tube is connected, not cracked, and the condition is water Leaking at the headliner vents or the DVD player area, suspect that the rear tube is restricted or blocked and proceed to REAR MOONROOF DRAIN TUBE CHECK AND REPLACEMENT.
NOTE
REAR DRAIN TUBES BEING RESTRICTED OR PLUGGED TYPICALLY WILL RESULT IN WATER DRIPS AT THE HEADLINER VENTS OR THE DVD PLAYER AREA.
3. Check for blockage or restriction at the front moonroof drain tubes by pouring water into the individual moonroof drain tubes (Figure 1), check for water backing up. If the front drain tubes are found to be restricted or blocked, proceed to FRONT MOONROOF DRAIN TUBE CHECK AND REPLACEMENT.
FRONT MOONROOF DRAIN TUBE CHECK AND REPLACEMENT
1. Remove the headliner, refer to Workshop Manual Section 501-05.
2. Remove the A-pillar trim, and grab handle and attaching metal bracket. Remove the lower kick panel to expose the sheet metal.
3. Remove the park brake pedal assembly, refer to Workshop Manual Section 206-05.
4. From underneath the dash, above the park brake assembly attachment, access the black rectangular plug. Remove the plug and reach in the opening and remove the white stuffer (Figure 3).
NOTE
FIGURE DOES NOT SHOW THE DASH BOARD, HOWEVER THE AREA IS ACCESSIBLE BY REACHING FROM UNDERNEATH THE DASH.
5. Remove the finger bracket from vehicle and move out of the way, the bracket is located below the park brake pedal attachment. Uncouple the wire harness (Figure 4) from the connector attached to the finger bracket, so the finger bracket can be moved out of the way. (Figure shows wire connector uncoupled).
6. Remove the rectangular baffle plug that is behind the finger bracket (Figure 5).
7. Check to see if restriction can be removed.
a. If restriction can be removed from the drain tube remove restriction and recheck for water leaks. Reassemble in reverse order.
b. If restriction cannot be removed, replace the front moonroof drain tube with part number 3L1Z-78502C52-AA. Proceed to Step 8.
8. Route replacement moonroof drain tube into hole in A-pillar (Figure 6). Start with the end of the tube that does not have the grommet. (Figure 6 shows a fully inserted tube).
9. While routing the tube through the A-pillar note that there are several "riv nuts" that the tube must be routed around. It is suggested to use some Dielectric Grease to lubricate the tube and/or add a weight to the end of the tube, which will help pull the tube through the A-pillar.
10. Once the tube is routed it will be visible through the access hole behind the rectangular baffle plug mentioned in Step 6.
11. Using a rod or screwdriver, push a hole through the foam baffle and insert the moonroof drain tube through the hole (Figure 7). Recheck for water leaks. Reassemble in reverse order.
REAR MOONROOF DRAIN TUBE CHECK AND REPLACEMENT
1. Remove 2nd row seat belt harness, refer to Workshop Manual Section 501-20A.
2. Remove C-pillar and D-pillar trim, refer to Workshop Manual Section 501-05.
3. Remove headliner, refer to Workshop Manual Section 501-05.
4. Remove module (Figure 8).
5. Peel back black insulation to access C-pillar cavity in front of wheel house at dog leg (Figure 9).
6. Remove white filler.
7. Remove the tube through access hole (Figure 9).
8. Check to see if restriction can be removed.
a. If restriction can be removed from the drain tube, remove restriction and proceed to Step 9.
b. If restriction cannot be removed, replace the rear drain tube with part number 2L1Z-78502C53-AA. Proceed to Step 9.
9. Cut 300 mm (12") off the end of the tube and route the tube back through the access hole in the C-pillar. Locate the end of the tube between the wheel well and outside quarter panel.
10. Secure the drain tube to the outside quarter panel metal to prevent it from moving. Recheck for water leaks. Reassemble in reverse order.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041509A Perform Diagnosis And 2.3 Hrs.
Reattach The Front Drain
Tube(s) (Includes Time To
Remove And Install
Headliner)
041509B Perform Diagnosis And 2.3 Hrs.
Reattach The Rear Drain
Tube(s) (Includes Time To
Remove And Install
Headliner)
041509C Perform Diagnosis And 3.5 Hrs.
Replace The Front Drain
Tube(s) (Includes Time To
Remove And Install
Headliner And Emergency
Brake Pedal Assembly)
041509D Perform Diagnosis And 3.5 Hrs.
Replace The Rear Drain
Tube(s) (Includes Time To
Remove And Install
Headliner)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78502C53 07
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