Ford Repair: 2007 exployer water leak, 2007, 2006

Question
Water leak remains after several trips to the dealer. With the kick panel off on the passengers side, water is leaking down col "A" to the floor, wiring is flooding in the water.  TSB for moon window drains has been completed.(Still leaks), windshield replaced (still leaks), drain line from moon rack located in col "A" replaced (still leaks)...When I poured water over door hinge area water would leak down col "A"..Dealer replaced rubber boot that holds wiring that goes into door.(still leaks..It appears leak is in the door hinge area..Could the hinges be leaking? What about damage to the electrical wiring in the floor channel, channel is flooded..help..

gene

Answer
Gene,

It sounds to me like you have a leak in either the windshield set or a high cowl to "A" post seam leak based on the fact that you can make it leak by pouring water in this area. I know the windshield set was replaced,but I would still check the lower right hand corner area with the interior trim off from the inside of the truck. The "A" post to cowl seams run right up to the bottom right hand corner of the windshield. Where does the antenna mount run through the body? Is it in this area as well? As for the question on the door hinges: I have not seen a leak such as that, for the reason being that the cowl section is a double wall panel that the bolts go through. This bolt up area is very tight by design. If it did have some small leak , it would run into the rocker drain area and out of the body.
Things to look at:
Windshield set
"A" post seams ( both upper and lower )
Roof panel seams
Cowl to "A" post seams
Bulkhead to wheel well seams
Any rubber plugs
Fresh air intake to plenum chamber

Hope this helps,
Drew Young
Rainchaser
Auto-Water-Leaks.com