I am told that a somewhat common issue that occurred in the pre-2008 Econolines is a leak under the windshield gasket--at the pinch weld that forms the window flange, right at the upper corners of the windshield, where two pieces of body sheet metal are joined.

As I understand it, the joint was not particularly skillfully done. This allows water to seep under the windshield gasket over time. That leads to rust, which leads to flaking, which then causes the sealant to separate from the metal. This allows water to seep into the A pillar, where it tracks down the pillar and drops down onto the carpet right below the A pillar on both sides of the van.

A similar issue occurred at the rain gutter at the seam in the back, where improper caulking can lead to rust and water entry just inside the rear doors.

It is my understanding that from 2005 to 2010, Ford provided what they termed a "Service Optional Repair" for this issue for owners who complained with sufficient vigor. The original Ford repair apparently involved exposing each of the affected areas, re-sealing, and then re-painting the entire roof.

Ford apparently issued some form of bulletin explaining the repair, but nobody I have spoken with at Ford has been able to locate that bulletin. From what I have heard, each repair cost Ford about $5,000, and they were eager to sweep the whole thing under the rug.

Has anyone:
1. Had this issue?
2. Had a Ford repair?
3. Performed an alternate repair?
4. Seen the service bulletin?

I have a minor form of this issue at my windshield, and I want to nip it in the bud, so I am looking to collect as much information as I can before I proceed with a repair.

 

I have this same issue. Did you find out anything?

 

I don't believe there's a gasket on these, they're installed with polyurethane. The only permanent fix would be to remove the windshield, see what's going on (good chance rust is the cause) and reinstall.

 

I remember JWA (auto glass expert) addressing this couple years ago, might what to do a search under his handle for the topic?

Had this booked-marked - FORD E-SERIES Factory Technical Service Bulletin - TSB | HelpForCars.net

 

Wildman25, when you referred to 'remembering' JWA posting something I had an 'Oh no' moment. I thought he was no longer posting on FTE. I had to do a search to find his latest post. Whew, he's still here!

Great to see you are still actively aiding the masses in need, much appreciated. I thank you guys for working so hard for the pay scale received.

 

Have not see JWA posting in a long time, don't know where he went to??

I just remember him addressing this topic several times in the past.

Me, if I have time, I try to add what I can, been and now back on the road for out of town work.

Pay scale received...........hehe..........It just cost me to "renew" my silver membership here...............but for all a good cause