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Old 08-19-2019, 07:45 PM   #1
doug022984
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Default Windshield Leak... or is it?

I have a leak. Ive had my headliner removed for weeks now trying to confirm if the leak is truly the windshield. With today's down pour, I'm now 95% sure it's NOT the windshield urethane gasket but actually leaking between the welded pieces of sheet metal that make up the windshield frame. Anyone see this before? I'm hoping someone may have a better knowledge of the steel panels to tell me if this is coming right from the outside at the windshield area, which is a little rusted... or if it's worse and coming in through the roof way in the back of the van and working its way between the panels up to he front. I'd prefer to treat the leak at the source, vs. just putting some RTV or something on that seam and then letting the water slowly rot way the van elsewhere upstream.
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Old 08-19-2019, 07:57 PM   #2
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Default Re: Windshield Leak... or is it?

You need to cut the cracked sealant out of the vertical seam, and fill it with fresh seam sealer. You may need to treat the rust in the area. If you are lucky, the rust hasn't spread under the windshield adhesive.
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Old 08-19-2019, 08:34 PM   #3
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Default Re: Windshield Leak... or is it?

Quote:
Originally Posted by Midwestdrifter View Post
You need to cut the cracked sealant out of the vertical seam, and fill it with fresh seam sealer. You may need to treat the rust in the area. If you are lucky, the rust hasn't spread under the windshield adhesive.


We went through the same thing on our 2005 high top. I talked to a windshield guy who said he sees this on older sprinters. His opinion was they flex and over time the seam opens up. We recaulked with a polyurethane. I wouldn’t recommend silicon. It’s an ok gasket material but isn’t the best for this application.

We did the repair 18 months ago. The second pic is where the leak ended up. Fortunately, I got it soon enough. We just had the original windshield replaced this summer and the rust was minimal. We wire brushed it, used some Ospho and primed it. Hopefully we’ll be good for another 14 years.
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Old 08-19-2019, 08:36 PM   #4
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Default Re: Windshield Leak... or is it?

Do you mean this seam? Any recommendations on "seam sealer" to use?
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Old 08-19-2019, 08:50 PM   #5
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Default Re: Windshield Leak... or is it?

Quote:
Originally Posted by doug022984 View Post
Do you mean this seam? Any recommendations on "seam sealer" to use?
yep, thats the one. It extends alongside the windshield until you hit the end of the roof panel.

For a quick and dirty repair, and urethane based paintable caulk-sealant will work.

I have not used this product, but it will likely work.

https://amzn.to/2YZFyXv

If you want something pro grade that will look good under auto grade paint, this will do the trick.
https://amzn.to/31UbGc5

You need to remove all the cracked/separated area. It may extend under the windshields trim. You can remove the trim (Be careful). Or you can clean as best you can, and fill the area under the trim with sealant. You would need to push it far enough under to contact the adhesive, and prevent water entry around the seam.
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Old 08-19-2019, 09:22 PM   #6
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Default Re: Windshield Leak... or is it?

Awesome thanks. I already have the windshield trim removed as can be seen in the picture since the glass edge is visible. I removed it to investigate and see if it was the windshield's urethane seal leaking. I also modified the trim already so that it doesn't hold water anymore. I basically cut the lip off so that all it really protects is the glass edge. Whenever I need my next windshield, I'm going to cut out the old one myself so I can do a proper rust repair of the whole area, but for now just trying to treat the leak.
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Old 08-19-2019, 09:39 PM   #7
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Default Re: Windshield Leak... or is it?

Even eternabond tape cut down to width may work for a quick fix.
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