Thought I'd post my experience with a leaking moonroof for other owners to read. Mainly it's to let others know what the local body shop began doing to help improve the integrity of Ford's moonroofs.

I've had this truck for about 6 months, and the latest leak caused water to drip out of the passenger side hand-hold in the pillar. I removed the pillar trim to confirm the water was running out of the head liner into the pillar trim and out the bolt holes in the hand-hold.

I had already brought the truck into the dealership previously for a leak at the rear of the moonroof. So we knew all 4 drain hoses were clear, and I drove straight to the dealership when I saw this leak as I left work. I needed them to see it happening since the last leak they couldn't reproduce.

The local Ford dealership doesn't have a body shop. So they outsource all their body work. What that body shop has found is the plastic moonroof framing isn't sealed adequately in the locations where Ford rivets sections together. Ford does put sealant between the pieces before they rivet them together, but sometimes that sealant isn't adequate, but even when it seems to be enough, the truck's vibration over time does one of two things. It either breaks loose a section of the sealant, or it creates a passage for water around the rivets & rivet heads.

So what the body shop has been doing for some time now(to more than just Ford's) is they apply sealant over the existing junctions. They apply sealant to where the plastic framing is joined, and they also apply sealant over the rivets too. This has proven to hold up in an environment where we get a lot of rain.

For what it's worth, once this leak started, I was soaking up 1/2C - 1 cup of water twice a day out of my Husky floor mats. Thank goodness for these mats that held the water from getting into the carpet!