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Leaking Sunroof in 2003 Expedition

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Old 07-10-2005, 11:01 AM
Blazer Dave Blazer Dave is offline
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Leaking Sunroof in 2003 Expedition

The sunroof in my 2003 leaks like mad and drips down the worst above the right rear quad seat right by the reading lamp. Is this a common problem? The sunroof on my 2001 leaked too and Ford wanted $350 or so for new gaskets. I'm tempted to just run a big bead of silicone around the top of it and just seal the danged thing off, I never use it. This is my LAST vehicle with a sunroof!
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Old 07-10-2005, 11:08 AM
Privateer Privateer is offline
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There is a TSB #04-15-9 dated July 21, 2004 that concerns moonroof leaks on the 2003 Expedition. The article states that the front drain tubes run down the A piller, and may come disconected by the grab handle. The rear drain tubes can be inspected by removing the door seal and looking under the headliner at the rear doors. The TSB has the complete data. I guess I've been lucky enough to not have any leaks on my 03 or 05 Expy's. Hope this helps.
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Old 07-10-2005, 01:26 PM
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Old 09-13-2009, 05:17 PM
02black250 02black250 is offline
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Anyone have the TSB 04-15-9 that they could email to me. Thanks.
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Old 09-13-2009, 07:15 PM
alloro alloro is offline
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Anyone have the TSB 04-15-9 that they could email to me. Thanks.
You can access the Recalls/TSBs section by clicking it up at the top center of this page. That 04-15-9 TSB seems to be gone, perhaps it's been superseded to this one (03-11-10).

https://www.ford-trucks.com/tsb/full...p?tsb=03-11-10
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Old 04-05-2010, 04:03 PM
Raceshopjen Raceshopjen is offline
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Sunroof leaking

I had the same problem in my 2003 Expedition, the sunroof was leaking in the right rear ceiling. I had a mechanic take the sunroof off, blow out the drain lines, and check around. After following the water trail, we determined it looked like it was coming from the luggage rack. We screwed the luggage rack in tighter and I have not had a leak since then. I have my fingers crossed... Unfortunately, I have been concentrating on much larger problems. The computer system is going berserk. I have had a "door ajar" for over a year now. Finally, I replaced the "door ajar" latch 3 days ago. It was silent for a day. Yesterday it came back on twice as bad. I had my mechanic play with the door latch and it was silent again. About an hour later, the battery light came on and started going on and off repeatedly with a message "check charging system". Also, some window switches are working sometimes and other times they don't. I'm guessing this is the computer going bad? Any advice would be great, as the constant dinging noise while driving is getting aggravating.
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Old 04-05-2010, 09:06 PM
Ammie Ammie is offline
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I also had the "door ajar" problem. I searched online and saw a post that said to spray each door lock latch with WD-40. It worked. Haven't had a problem since.
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Old 04-06-2010, 05:12 AM
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Quote:
Originally Posted by Raceshopjen View Post
I had the same problem in my 2003 Expedition, the sunroof was leaking in the right rear ceiling. I had a mechanic take the sunroof off, blow out the drain lines, and check around. After following the water trail, we determined it looked like it was coming from the luggage rack. We screwed the luggage rack in tighter and I have not had a leak since then. I have my fingers crossed... Unfortunately, I have been concentrating on much larger problems. The computer system is going berserk. I have had a "door ajar" for over a year now. Finally, I replaced the "door ajar" latch 3 days ago. It was silent for a day. Yesterday it came back on twice as bad. I had my mechanic play with the door latch and it was silent again. About an hour later, the battery light came on and started going on and off repeatedly with a message "check charging system". Also, some window switches are working sometimes and other times they don't. I'm guessing this is the computer going bad? Any advice would be great, as the constant dinging noise while driving is getting aggravating.
X2 on the WD-40 in the door latch. I've read many successes with that. This may be your problem with the "charging system also. If the computer thinks a door is open, then the courtesy lights are probably staying and draining the battery down. Thankfully the system has a timer and will automatically shut them off eventually (the kids have turned mine on and forgotten about them a number of times). The repeated drain of the lights may have finally wore out the battery. Or maybe it's just time to replace some parts. I had both my battery and alternator go bad last summer, though I'm sure one's failure caused the other's failure.

As for the switches, they may just be going bad. The switch for my power quarter windows almost never works now. Three years ago it almost always worked.

Bottom line, you probably don't have a computer problem, just an age problem. Parts wear out.
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Old 04-06-2010, 11:05 AM
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alwaysfords41 alwaysfords41 is offline
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I agree with the WD-40, I had typed a reply to you yesterday but forgot to post it. The switches can very often be saved by taking them apart and cleaning off the contacts. They trap lots of lint and gunk over time. Open them up, blow them out and clean off the contacts and I'd bet 99% of the time they will go right back to working. You could also try an air blow with out even taking them out on the chance the lint is not all gummed up with oil, etc. and will just blow out. As mentioned, stuff breaks over time.
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