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Why do aero windows leak?

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Old Aug 1, 2006 | 01:52 PM
  #16  
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I think ford used some kinda foam core butyl. I'm guessing thats the problem.


Dick
 
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Old Aug 20, 2006 | 02:38 PM
  #17  
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It may also be the panel sealer. Mine leaked at the roof line.
 
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Old Aug 20, 2006 | 03:17 PM
  #18  
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On the roof near the sides there are two channels that seem to be formed by the roof and side panels joined together with some kind of hard sealer. In my case, these sealer started to walk away from the metal in some places, and the resulting gap allowed moisture to get to the metal, which further resulted in rust. My fix was to first clean the areas out with metal prep (I think it's mostly phosphoric acid) to get rid of the rust. Then sealed the gaps with clear RTV. Since it's on the roof, no one will really notice the fix, so I didn't bother to try to paint over it. You can't paint over RTV anyway.

This isn't quite the same as a rear window leak, but I know that if I didn't take care of it, it would have gotten worse, probably turning into a rusty roof leak.
 
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