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Sunroof Leak Fix - pics of process

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Old 12-15-2011, 11:05 PM
bobwires bobwires is offline
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Sunroof Leak Fix - pics of process

We have a regular customer that had a leak issue we offered to fix. '00 Expedition, but I'm sure it's a similar setup on explorers, etc.

There is a TSB about the sunroof rail guides breaking due to customers manhandling them. If you slide the the little sunshade back too violently it will break off these little tabs and/or loosen the little screws that hold the rear drip rail in place.

We determined the issue when we pulled the headliner and found the metal drip rail all jammed up in there diagonally, scratching things up. Both guides were broken. Ordered up the new guides with the metal rods, and a pair of drain tubes for the front.





You have to drill out these rivets and power the glass back and forward to get the guides and rods out.



Here's the rear rail back in







Here's the dumb kinked tube. Nice S-shaped kink.







I hope this helps some of you.

Where do these front tubes exit the vehicle? They go down the a-pillar through the drivers kick panel, and I can't see an exit point!
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Old 12-16-2011, 03:30 AM
alloro alloro is offline
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Nice pics of the drain hose repair.

If you want to save your customers a bit of cash try the bent washer trick: http://www.ford-trucks.com/forums/35...l#post10841056
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Old 12-16-2011, 05:31 PM
NemesisNJ NemesisNJ is offline
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Just curious where you got parts for this fix. I too have an issue with the sunroof, pulled it out along with the headliner. The plastic rail guides are cracked, and the 2 rods are bent. I too may need a new water trough or just screws, I forget exactly it was awhile ago. My leak was from the one guide being farther down the wire than the other, I wasn't getting a good seal, when I closed the sunroof, so water would come pouring in around turns either thru visor mount or another. I did locate parts from "The Sunroof Doctor" all I need for $119. But Ford doesn't list the pieces I need on the diagram at all, but every other part around it, that I don't need. When I did have it apart I checked the hoses and they were all fine, no crimp no clogs. Any help would be appreciated.
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