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I have an '80 Bronco and over the past year or so I have replaced every weather seal there is to replace, repaired holes in the floorboards, replaced rear window weather seals and the tailgate seal. I have plugged airspaces in the firewall where various hoses and wires enter the interior. I have lifted the cargo area mat and inspected the floor panels for holes.
In spite of this, after driving down a dusty country road with the windows down--the ac does not work--I notice a thin film of dust over the rear seat, dash and other areas. Where in hell is this getting in?
I am beginning to suspect the cancer-eaten front driver side fender. The rust has caused an opening into the engine compartment. Could this be the cause? however, I have a friend who has a '79 Bronco with a restored body--no cancer eaten fenders like mine--and he says he also has this problem.
You could try various thicknesses of weatherstripping on the doors, and run it all around the door, not just at the top where the factory puts it. Then seal the vents they put in the door, I think they are either behind the map pockets or on the inside edge. Do the same with the weatherstripping for the rear tailgate.
Also, I remember reading something where a magazine took out the grate for the AC air intake and made a foam and screen filter type setup that cut down on the dust through there. No idea on how often you had to clean it or if it worked long term. They said with the AC on the truck seemed pressurized.
Okay, you got me guys! You comedians are too much.
I should have been more specific:
Driving down a five mile stretch of dusty country road on a sunny, 95 degree day is not conducive to driving with the windows up! The AC does not work, and I am not planning on paying big $$$$ for a couple pounds of R-12 Freon until my son gets out of college. My Bronco has no headliner and heat radiates from teh metal top into the interior, so on these hot days, only a masochist would drive with all windows up.
I do not drive with the tailgate window down--even if I only have the driver side window down the dust problem occurs. with teh windows up, the problem occurs.
I have ridden in many vehicles with the windows down and dust does not enter and coat everything. A vehicle running along generally leaves the dust cloud below the level of the windows and behind the vehicle and it does not roll up the sides of the vehicle and into the windows unless you stop and the dust cloud catches up or a vehicle passes in the opposite direction.
The windows are NOT the source of the dust. When driving along suddenly a fine knee-level dust cloud is perceptible in the Bronco.
You probably already have, but I'd really focus on the area around the tailgate seal and glass run. When you're driving, air passing under the truck tends to roll right back up against the back (which is why tailpipes exiting straight out the back aren't recommended on a Bronco). If you're driving that much on dusty roads, and you're getting that much of a problem with the front windows up or down, any small leak in the rear gate seal or around the glass would likely let the dust in. (I'm assuming your inner rear wheel houses and sheet metal aren't rusted through, or anything.....)
I guess anything is possible, but I wouldn't think so. While the exterior quarter panel may be rusted through, the inner panel should be keeping things closed up (unless, of course, the inner is also rusted through, but it doesn't seem likely).
I have the same problem, I think the dust came factory installed. Look in your owners manual and see if it was an added option. haha. Nahh, I accually do have the same problem and have gone threw all you have. I accually took out all my seat and beat them out for two days in a row. Try that and see if it helps.
[updated:LAST EDITED ON 14-Sep-02 AT 01:57 AM (EST)]Have you checked to make sure the transmission access plate is properly sealed? That would be a good place for dirt to enter, and is easily overlooked.
My other thoughts would be a hole in the floor for a bolt that is missing.
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