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I haven't looked into this further but I do know that I don't have a rust problem. If I have a roof seal problem I'll add "sticky rubber" and seal with silicone if needed. I have some minor cracks in the "gutter" (drip rail molding). I'll fill them with touch-up paint and then seal with silicone and go from there.
Hey guys their is a TSB out on the rain gutter problem for our Broncos. I don't believe it has anything to do with rust. The rear area around the back of the rain gutter cracks and leaks giving you the wet carpet behind the seat. I siliconed mine a couple of years ago and it worked good as a temporary fix. I have to check mine again becuase I tink it's leaking again.
The TSB mentioned a repair kit which contained some reenforcing brackets that go up under the headliner. So I'm assuming that the cracks are caused by stress.
I siliconed the rain gutters. I still have moisure but now its not near the rear speakers but the far back right of the truck! I think the tailgate window has bad weatherstripping. Anyone encounter this? I'll update the silicone rain gutters after a couple of rainstorms. (It's actually snowing in NJ right now)
When it is wet out and you are driving down the road at 55+ water will seep in and run anywhere. Check your door seals as well. On the older models you can get seals from after market sources like LMC Truck and JC Whitney. But for my buck, I will get it from Ford whenever I can. I bought an aftermarket upper tailgate window seal from JC Whitney and it just doesn't fit right. Get the right stuff from Ford. Don't go with some rubber stuff that you stick in with a paint stick. I don't imagine it would look all that good.
hey guys. where I live we get 200 inches of rain a year and finding leaks (guessing leaks) can become very frustrating. I had the same problem with the carpet on the back floor getting wet, and to find it with out spending the rest of my life doing it i took out all the carpet and the cargo panels, cleaned everything up, and just watched. I actually had it in two spots. one leak was from the side window all the way in the back and running up to the back seat floor, and the other was a rust holein the inner quarter near the speaker hole.
All the big Broncos have stress problems at the rain gutter. I had a friend who bought a '93 brand new and Ford cut the entire top off twice trying to eliminate the problem. He never took the thing off road either. That was the worst case I ever saw but you see a few Broncos with the tell tale spider cracks at the trailing edge of the gutter. I have the same problem on my Centurion Conversion but it's a little more involved because the Bronco roof is spliced to the crewcab roof. My bodyman says he can fix it though...all it takes is money.
:-staun
http://groups.yahoo.com/group/centurionconversions/
Rezvani's Latest Post-Apocalytic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.