Drivers side footwell rust - Where is the water coming from? (1 Viewer)

[TomLaw88]

Hi folks,

I have rust in the driver side footwell as pictured. Luckily all of it is pretty thin so not major structural issues. It looks like the water was getting trapped under old sound deadening that had hardered and insulation under the carpet.

What I can't figure out is where it's coming from. I'm assuming it originates from the hole down to the bolt that holds the bed to the frame but when I look inside there is no water damage. I checked the sunroof drains and they are working fine. If I look at where the bungs are in the bed there is no water damage here either. The heaviest damage is around the hole still and doesn't go any further up into the footwell. I checked the panels under my LC and no water major damage here either.

Has anyone seen this before? Where else should I look? Should I seal the hole shut? (no plans to lift the bed from the chassis for the foreseeable future)

For reference this is a '91 FJ80

Thanks,
Tom

 

[BreezyF]

Have you checked under the vents above the hood in between the hood and the windshield. Mine was having the same problem but no sun roof. This whole center area was plugged with debris and would not allow it to drain

 

[Malleus]

It's either your sunroof overflowing or it's the windshield. Your drain tubes can be clear, and the sunroof pan will still overflow into the A-pillar. The sunroof seal is designed to slow the infiltration of water until the drains can evacuate it. If it doesn't seal completely, and none do anymore, it'll leak into the A-pillar.

 

[Malleus]

Have you checked under the vents above the hood in between the hood and the windshield. Mine was having the same problem but no sun roof. This whole center area was plugged with debris and would not allow it to drain

View attachment 3442252

View attachment 3442253

The cowl drains over the top of the inner fender, not into the cabin.

 

[BILT4ME]

I'm guessing windshield is the most likely candidate, especially if it has ever been replaced.

This is why we get so anal about proper installation of it.

 

[TomLaw88]

It's either your sunroof overflowing or it's the windshield. Your drain tubes can be clear, and the sunroof pan will still overflow into the A-pillar. The sunroof seal is designed to slow the infiltration of water until the drains can evacuate it. If it doesn't seal completely, and none do anymore, it'll leak into the A-pillar.

So replace the sunroof seal is what I'd need to do here?

 

[TomLaw88]

I'm guessing windshield is the most likely candidate, especially if it has ever been replaced.

This is why we get so anal about proper installation of it.

What is there to be anal about? Should I go to a specialist for replacement or is safelite adequate?

I can see some surface rust under the seal so makes sense to replace.

 

[Malleus]

So replace the sunroof seal is what I'd need to do here?

You can't. It's not available as a separate component and the sunroof isn't available any more. The only solution is to reroute the drains thought the floor of the fenderwell pocket instead of the rocker panel. Toyota did this in later models.

 

[Malleus]

What is there to be anal about? Should I go to a specialist for replacement or is safelite adequate?

I can see some surface rust under the seal so makes sense to replace.

Safelite will not replace the windshield using the FSM procedure. Their procedures are for newer windshields that are glued directly to the body without a rubber gasket. They will use that procedure to glue your windshield in and it'll leak.

You have to find someone who's done it before and knows how to do it correctly. The gasket has to be glued onto the glass and then installed, and then glued into the frame. And the correct adhesive has to be used. The adhesives glass replacement companies now use are designed for glass to metal, not rubber to metal or rubber to glass.

 

[BILT4ME]

What is there to be anal about? Should I go to a specialist for replacement or is safelite adequate?

I can see some surface rust under the seal so makes sense to replace.

Look up "windshield" onhere and you'll find a number of threads about how improper installations leak and cause problems.

My 96 had a replacement by the PO and when they did it, they scratched around the frame, causing rust.

I now have a cracked windshield and need to replace it. When the seal is removed, I KNOW I will find rust because I also discovered my windshield has been leaking (wet carpet under my floor mats). So now, I have to plan for having the frame cleaned, rust proofed, painted, cured, then the new windshield and gasket (Toyota ONLY for the gasket) and installed with proper sealant on BOTH inside and outside of the gasket.

I have already had one company tell me to go away because I insisted they use a Toyota gasket and that I was going to provide the FSM instructions and watch them do it.

 

[Malleus]

Although it won't help you, ToyotaPartsDeal claims to have the '95-97 glass in stock

 

[TomLaw88]

You can't. It's not available as a separate component and the sunroof isn't available any more. The only solution is to reroute the drains thought the floor of the fenderwell pocket instead of the rocker panel. Toyota did this in later models.

Thank you for the responses!

I'm looking for guidance on this procedure but coming up short, are you aware of anything? Sorry to ask because I know search is my friend but Im still struggling.

 

[TomLaw88]

Although it won't help you, ToyotaPartsDeal claims to have the '905-97 glass in stock
View attachment 3442269

$500 + $500 for shipping....probably.

 

[Malleus]

FWIW, the original adhesive isn't made by the original supplier to Toyota dealers. However, Dupont Betaseal U-418 is an acceptable replacement.

 

[Malleus]

$500 + $500 for shipping....probably.

I'd pay that. The OEM glass assy lasted 28 years. I won't be driving when this one reaches that age, if I'm alive then.

 

[Malleus]

Thank you for the responses!

I'm looking for guidance on this procedure but coming up short, are you aware of anything? Sorry to ask because I know search is my friend but Im still struggling.

The FSM is in the Resources section in the 80 section, for free download. Windshield replacement procedures are common to all 80 series trucks.

You might as well download the EWD while you're there.

 

[BILT4ME]

I'd pay that. The OEM glass assy lasted 28 years. I won't be driving when this one reaches that age, if I'm alive then.

@OGBeno has confirmed that the OEM glass is NLA despite what Toyotapartsdeal says.

I trust his judgement since he has direct information into the system.

 

[BreezyF]

The cowl drains over the top of the inner fender, not into the cabin.

Idk if it was so backed up it found a place to go but since cleaning she’s stopped

 

[open country]

Although it won't help you, ToyotaPartsDeal claims to have the '905-97 glass in stock

They frequently list stock for NLA parts, they'll take your money then never ship it.

 

[CharlieS]

Although it won't help you, ToyotaPartsDeal claims to have the '95-97 glass in stock
View attachment 3442269

I wouldn't trust Toyota Parts Deal for anything. Horrible business practices, in my experience.