lil water
I know in my audi i was preety much the same problem and it was a lil drain hose witch was stuff with dirt as soon i clean in it was fine so maybe it is some same drain problem in my car
05 Ford E-150 Chateau thx
The Econoline 'doghouse' has a fairly good reputation for sealing against water, exhaust & noise. However it can have issues & require tweaking to assure a good seal all around.
Try placing cardboard/newspaper over/off of "wet carpet spot" in downpour to detect dripping leak from above, if you haven't already eliminated that possibility. Windshields are essentially glued in & can leak. Holes thru cowl for wiper pivots can leak.
Wouldn't expect it on an '05, but if rusty could have hole in floor, or somebody might've drilled a hole & not sealed it well.
Fresh air duct can leak, but on pass side.
The windshield is essentially glued in & the urethane adhesive is hidden behind a black mask, preventing it from being inspected. Bond failures allow water to enter & it can get channeled well away from where it's leaking.
A Chateau has lots of extra insulation that can sop up water & get soaked, only to let it drain elsewhere. This can disguise where water is coming from.
If no water inside the expand the area you put the water on till you find the leak.
Did this with my old Expedition and found a leak in the cowl area.
If no water inside the expand the area you put the water on till you find the leak.
Did this with my old Expedition and found a leak in the cowl area.

If you notice the leak on top of the carper or factory floor mat the leak comes from above whatever surface is wet. Its highly unlikely the metal floorboards get so wet the carpet and its padding become thoroughly soaked. There are occasions where high humidity and sudden drops in overnight temps causes a condensation issue with rubber mats and inside cargo vans but your Chateau shouldn't experince this same thing.
Begin with a bright light and yourself inside the cab, all doors and windows closed As PT suggests run a hose over the front but no higher up than the hood/cowl area, making sure you soak the entire width continously for at least 10 minutes. Leaking water sometimes takes a while to find its way inside the cabin unless its huge---doesn't sound like yours is though. Look for obvoius drips---if any develop simply look upward then follow it to the approximate area outside to see if a simple application of a body sealer would fix it.
If no leaks are discovered with the hose at the hood level next is to start moving the running water up the A pillar or post in which the windshield is mounted. This is a slower process because water can take quite a long and winding path where its dripping is noticeable. As you s-l-o-w-l-y move the water hose upward continue looking for drips.
As you approach the top pay careful attention to the body seam where the corner of the windshield sits. This seam has a tendency to split or open, sometimes under the winshield molding and unseen to the eye. If no drips move the hose more to the center of the windshield and continue looking for any obvious drips.
I will say sometimes these leaks can't be seen with interior trim panels installed. I've worked on some vans with original windshields installed where the metal floor was very rusty from a leak that had traveled completely under trim panels and carpet/mats, never a visible sign anything was amiss.
This ususally isn't a quick and easy process if the leak isn't quickly found. If your patience becomes exhausted call a good independent glass shop OR a trusted body shop and get some quotes. Occasionally I've spent several hours over different days looking for and finding similar leaks. E vans are known for the A pillar body seam splitting even on vehicles never involved in collisions. Its just one of those things that sucks but being aware or what or why might be helpful.
Feel free to PM me if I can be of any help at all!
Persistant leaks that "cling to surfaces" by a force known as surface tension, don't "drip" they dribble, defying gravity. Such leaks often develop telltale stains tracing their "paths". These stains tend to be more easily seen when dry. Leaks under/inside windshield/cowl area from various faults, that "trickle down" on the toeboard, can easily "redirect" water under carpet w/o any "obvoius drips".







