My 03 expy leaks like a sieve in carwashes. The passenger upper corner takes in water and pours out (believe it or not) the visor bracket and the grip handle bracket. The outside rubber molding appears the same as on the driver side. I think the large rain channels in the roof bring water under the rubber molding upper lip by design (1/4" clearance between upper lip and roof). Then, there is a lower lip that appears to seal to the roof. But why even allow water under the upper lip to begin with? Is the water meant to travel in a channel inside the A pillar? I feel like caulking the channel opening in the rubber molding on both sides. Any thoughts here? Thanks.

 

Is it under warranty?
Have you had the truck since new?
Did you have a windshield put in it? If so, bring it back to the shop that did it and have them fix it. Most shops have a lifetime no-leak guarantee.

 

I bot it used from a salesman who traveled extensively and the high mileage (88K)voids warranty. According to his repair records there was no windshield replacement.

 

This should not cost to much. I had a leak in my 2000 and I had the windshield pulled and resealed for about $100.00. NO more leak. If you search this forum you will find that alot of the EXPD have had this problem.

 

same here, shortly after i bought mine i had a small leak on the driver side. Asked the sales guy if he would do anything bout it and he said sure. they took it to a glass shop and had them pull and reseat the windshield. Problem solved

 

Thanks - I will have it resealed.

 

Funny that I found this message as I was just about to post about my own leak. I just traded my '98 EB for a 2003 EB with 57K miles (no warranty). I've had it for about 2 weeks, took it to the car wash yesterday for the first time and found a leak. The carpet on the driver's side floor was wet, mostly where the heel pad is on the left. I also noticed that the parking brake pedal was wet. While driving home some water came out of the visor mount on the left and I felt water hit my leg from around the very bottom of the plastic console.

Looking at the rubber seal around the windshield on the top corner (driver's side) I notice that it does not look as tight as the passenger side. Nothing I would have noticed as a problem, just looks a little bit loose in comparison. Is there any reason not to squirt some sealant under there and see if that helps?

Researching on here I saw a few people posted about a TSB on the sunroof seal. Is this confirmed? Can anyone point me to the TSB number in case I take it to the dealer?

Also, driving to work this morning I had what seemed to be an electrical glitch. Stopped at a light, I noticed the engine felt a little rough. Then, once on the highway, the Check Engine Light Soon light began flashing and warm air came through the A/C vent. I turned off the A/C and slowed down a bit. After a minute or so the light stopped flashing and turned off. Engine seemed to be running OK after that, but it was only another 2 miles or so to my office. I am assuming this is related to the water leak. Anything else I should look at here?

 

Sounds like to me you have water into the GEM and or fuse box. I had the same problem till I got the windsheild pulled and resealed.

 

With regards to the TSB on the moonroof seal, does the factory pay for that even though I am out of warranty or I am stuck with the fix due to the mileage?

 

you pay for the repairs if it is out of warranty.