Fulltext TSBs

Technical Service Bulletins

TSB
01-1-11
  • WATER LEAK – SLIDING REAR WINDOW – VEHICLES BUILT THROUGH 4/1999
Publication Date: JANUARY 11, 2001

FORD:
1997-1999 F-150, F-250 LD

ISSUE:

Some vehicles may exhibit a water leak around the rear (sliding) window. This may be caused by a crack in the plastic frame around the window and/or deterioration of the butyl seal between plastic frame and cab.

ACTION:

Remove the rear sliding window module and apply a gusset seal. Reinstall the same window module. The gusset seal should reduce the possibility of leaks. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

NOTE:PREVIOUSLY, WHEN A SLIDING GLASS REAR WINDOW ON AN F-150/F-250 LD WAS FOUND TO BE LEAKING, THE SERVICE PROCEDURE WAS TO REPLACE THE LEAKING WINDOW MODULE WITH A NEW SLIDING WINDOW MODULE. THE NEW PROCEDURE DETAILED IN THIS TSB DESCRIBES HOW TO USE THE SERVICE FIX SEAL TO REPAIR AND REUSE A REAR WINDOW MODULE.

LEAK CHECK THE REAR WINDOW

  1. From inside the cab, check to make sure sliding pane is latched closed and area around window is initially dry.
  2. Spray water at moderate pressure into margin between window module and halo moulding around window module.
  3. From inside cab, check for water dripping down inside window. In particular, look for drips coming down the side (fixed) panes of the window.
  4. If water is coming through the seals that seal the sliding pane itself (a less common leak path), the gusset seal will not correct the leak and the window module will need to be replaced.

APPLY REAR WINDOW GUSSET SEAL

  1. If rear window is found to be leaking, remove it according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. Take care when removing it to not damage it or the cab sheet metal around it. Try to minimize bending of the window module.

    NOTE:IF THE VEHICLE WAS BUILT PRIOR TO 2/1998, THE HALO MOULDING (STILL ATTACHED TO THE CAB) THAT NORMALLY FRAMES THE REAR WINDOW MODULE HAS TABS ON IT THAT NEED TO BE REMOVED. THESE TABS (NOT PRESENT ON VEHICLES BUILT AFTER 2/1998) HANG DOWN FROM THE UNDERSIDE OF THE TOP OF THE HALO MOULDING. THEY ENGAGE SLOTS IN THE BACK OF THE TOP OF THE WINDOW MODULE AND MUST BE REMOVED PRIOR TO REINSTALLATION OF THE WINDOW MODULE.

  2. Check if the window module is repairable.
    1. Look for vertical cracks in the plastic division bars that separate the fixed from the sliding panes.
    2. Look for separation of the side panes from the plastic frame.
    3. If either of these conditions are present (usually caused by excessive bending during removal), the module can’t be repaired and needs to be replaced with a new module.
  3. If the window module is repairable, obtain the Gusset Seal (XL3Z-1542086-AA) and the Standard Butyl Sealing Cord (E69Z-19562-A).
  4. Thoroughly clean sheet metal opening in cab of residue from previous butyl seal. Butyl can be used to “blot” butyl off of the sheet metal. If the surface is not properly cleaned of all residue, the window may leak after it is reinstalled.
  5. Clean the back of the window module of the previous butyl seal using the methods described. Additionally, clean the top of the window module. Pay particular attention to the lip of the glass that extends above the frame. This lip of glass (the side on top of the module) must be clean for the gusset seal to adhere properly.
  6. Place short (25mm/1″) sections of standard butyl sealing cord behind the gaps between the side panes of glass and the division bars (Figure 4). Make sure the butyl seats against the plastic frame at the bottom of the gap. If this is not done, the gaps provide a leak path for water to get by the gusset seal.
  7. Leaving the release tape in place, unpack gusset seal and refer to remaining Figures 1-3 to understand how the seal will be applied to the window module.
  8. Notice that a standard butyl sealing cord is applied to the window before the fix is applied (Figure 2).
  9. Leaving the release tape on, apply a standard butyl sealing cord to the back of the window module taking care to lay the butyl in the “track” moulded into the plastic window frame.
  10. Place window (back side up) on a clean, stable surface with the top edge of the window module facing you. The gusset seal will be applied to the top edge (Figure 3).
  11. Check Figure 1 and find the pre-attached butyl seal that is to be applied to the back edge of the glass. This edge of the gusset seal is thick, rather than flat. Remove the release tape from this butyl seal only.
  12. Once installed the gusset seal should extend from one stud on the sloping side of the window module to the opposite stud on the opposite sloping side of the window module (Figure 2 and Figure 3). In the process, it should cover the entire top of the plastic frame behind the glass and down to just above the row of studs across the back of the module.
  13. Starting at one side of the module, apply the butyl bead (exposed in Step 12) to the crevice between the back of the glass and the top of the module. It is important that the butyl seals to the glass in order for the gusset seal to not leak. Additionally, try to minimize the protrusion of the seal onto the visible side of the glass. It should be below the rounded edge of the glass.
  14. Moving across the top of the module, apply the butyl bead on the edge of the gusset seal to the back of one fixed pane, the plastic lip above the sliding pane, and then across the back edge of the other fixed pane. Make sure that the butyl on the gusset seal seals to the two (2) small pieces of butyl applied in Step 6.
  15. Remove the release tape from the standard seal applied in Step 9. Refer to Figure 2 to see how the gusset seal is applied to the standard butyl seal. Starting at one side, stick the back of the gusset seal to the standard butyl seal. At this point, the gusset seal should cover the entire top of the window module down to the row of studs.
  16. Remove the release tape from the second butyl strip on the gusset seal. This will seal to the back of the cab.
  17. Reinstall the window module according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual.

PART NUMBERPART NAME
XL3Z-1542086-AAGusset Seal
E69Z-19562-AButyl Seal

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATIONDESCRIPTIONTIME
010111AReplace Sliding Window Seal1.7 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
1956201

OASIS CODES:

102000, 108000, 110000




Figure 1 – Article 01-1-11




Figure 2 – Article 01-1-11




Figure 3 – Article 01-1-11




Figure 4 – Article 01-1-11


Copyright © 2001 Ford Motor Company