Headliner water leak

[Dr Gil]

I've read virtually all the threads about sunroof and windshields leaks and fixes. I have a water that leaks from the driver side headliner / windshield seal junction. Water only leaks when I turn left.

I've replaced the windshield with an OEM windshield seal.
I've cleaned out all 4 of the sunroof drains with air pressure, water, and braided cable.
I've cleaned all 4 of the rocker panel slits to be sure there is no clog in the rocker panels.
I've done the bicycle tire inner tube repair.
I've done the kitchen string repair.
I've taped up the entire sunroof junction on top of the roof and tested for water leaks. The windshield tech assured me there cen no leak at the sunroof with all that tape up there.

I still get the water leak. I also feel a few drops of water on my left leg when that water leaks up at the headliner.

What other possibility is there to find this water leak?

 

[voodu3]

Did the windshield installer use sealant on both sides of the windshield seal? My guess is they didn’t or there is a gap in the sealant on the body side of the seal. When I resealed mine i had a similar issue. I went back and found one spot without any sealant. I put more on and it’s been dry since.

 

[Dr Gil]

Did the windshield installer use sealant on both sides of the windshield seal? My guess is they didn’t or there is a gap in the sealant on the body side of the seal. When I resealed mine i had a similar issue. I went back and found one spot without any sealant. I put more on and it’s been dry since.

Yes, he did. He researched and read the FSM before I brought it in, and I gave him a copy of the pages to follow from the FSM.

 

[COYS]

Yes, he did. He researched and read the FSM before I brought it in, and I gave him a copy of the pages to follow from the FSM.

He likely didn’t do it right.

 

[Dr Gil]

He likely didn’t do it right.

Maybe, but I have to assume he did do it right. He had the proper FSM information and he's experienced.
It's leaking from the same place it did before I brought it to him for the windshield and seal replacement.

 

[Kernal]

Random thoughts (assuming the tape over the gap between the glass and roof is leaking somehow): if the sunroof assembly has drooped that will allow too much water to get past the seal but then you have the inner tube already so IDK how likely that is, just something to check. If the sunroof glass can be pushed significantly upward from inside then it has dropped. Adding extra shims around the sunroof studs will bring it upward. IIRC the thicker shims may be NLA but you can use any U type shim or even common washers.

Another source is from around the black plastic cable covers at the front of the sunroof, you can put some butyl rubber (rope/ribbon) under those covers to make a little dam of sorts so the water from the sunroof drain pan doesn't overflow as easily. But then again, if the tape has sealed the gap then no water should be getting to the drain pan at all.

Other than a leak around the windshield only other source I can imagine might be a rust hole under the port installed roof rack components on the that side??

 

[Dr Gil]

Random thoughts (assuming the tape over the gap between the glass and roof is leaking somehow): if the sunroof assembly has drooped that will allow too much water to get past the seal but then you have the inner tube already so IDK how likely that is, just something to check. If the sunroof glass can be pushed significantly upward from inside then it has dropped. Adding extra shims around the sunroof studs will bring it upward. IIRC the thicker shims may be NLA but you can use any U type shim or even common washers.

Another source is from around the black plastic cable covers at the front of the sunroof, you can put some butyl rubber (rope/ribbon) under those covers to make a little dam of sorts so the water from the sunroof drain pan doesn't overflow as easily. But then again, if the tape has sealed the gap then no water should be getting to the drain pan at all.

Other than a leak around the windshield only other source I can imagine might be a rust hole under the port installed roof rack components on the that side??

Kernal, good thoughts on this.
I have already added OEM shims to the glass so that is likely not an issue.
I have double layered Gorilla tape over the sunroof gap and roof, so that is not likely a cause of water leak.
No OEM roof rack since I've owned the LC for 13 years.

 

[SpenserAK]

Hopefully not in your case, but sharing a possibility. My truck was in very good condition including paint overall, frame, etc. However, for whatever reason there was a corrosion spot about the size of a tennis ball imprint on the roof. One day I went to grind the corrosion, reseal, and repaint, Which lead to discovering a pea-sized hole through the roof metal. I then inspected a couple other roof areas with light spider cracking in the paint and found a few more small holes. That's one way water could get on top of your headliner, which would be unrelated to everything else you've done, which I'd also done. Once I had addressed the full range of issues mentioned in this thread, never had another water intrusion, and I live in a pretty damn rainy place.

Do you see any water stains on your headliner?

 

[Dr Gil]

Hopefully not in your case, but sharing a possibility. My truck was in very good condition including paint overall, frame, etc. However, for whatever reason there was a corrosion spot about the size of a tennis ball imprint on the roof. One day I went to grind the corrosion, reseal, and repaint, Which lead to discovering a pea-sized hole through the roof metal. I then inspected a couple other roof areas with light spider cracking in the paint and found a few more small holes. That's one way water could get on top of your headliner, which would be unrelated to everything else you've done, which I'd also done. Once I had addressed the full range of issues mentioned in this thread, never had another water intrusion, and I live in a pretty damn rainy place.

In my case, that is not a possibility. I've been up on the roof and closely inspected the entire roof. I only have clear coat damage, no rust, no corrosion on the roof.

 

[Kernal]

Seems the only culprit left is the windshield??

 

[Dr Gil]

Seems the only culprit left is the windshield??

I’m speaking with the windshield installer tomorrow, but I’m sure he’s going to say it’s not the windshield, the leak was in the same place that it was before I brought it to him

 

[Kernal]

When my 96 model had a windshield leak (after a second botched installation) I took it to the best glass installer in the region and he spent almost an hour with a garden hose looking for a leak. He worked very methodically, one section of the windshield at a time with the kick panels off both sides and climbing all over the vehicle and upside down in the foot wells with a strong flashlight before he found the leak (from the windshield).

 

[Dr Gil]

When my 96 model had a windshield leak (after a second botched installation) I took it to the best glass installer in the region and he spent almost an hour with a garden hose looking for a leak. He worked very methodically, one section of the windshield at a time with the kick panels off both sides and climbing all over the vehicle and upside down in the foot wells with a strong flashlight before he found the leak (from the windshield).

You are correct there is always that possibility there is an installation error. This installer has an ultrasonic leak detector so I will have them do that again and see if he can find any kind of leak around the windshield.

 

[Brindleboxer]

In my case, that is not a possibility. I've been up on the roof and closely inspected the entire roof. I only have clear coat damage, no rust, no corrosion on the roof.

Do you have a factory/port installed roof rack? If so, I would suggest pulling it and checking under the feet. I had a similar leak and thought it was the sunroof only to find that I had rust under the front feet of the roof rack. Mine would not leak all the time but when it did it would leak from the seam where the A pillar headliner assembly met the main headliner (mine is a 94 so your headliner assembly is a little different but is inconsequential to this).

 

[Dr Gil]

Do you have a factory/port installed roof rack? If so, I would suggest pulling it and checking under the feet. I had a similar leak and thought it was the sunroof only to find that I had rust under the front feet of the roof rack. Mine would not leak all the time but when it did it would leak from the seam where the A pillar headliner assembly met the main headliner (mine is a 94 so your headliner assembly is a little different but is inconsequential to this).

As per my previous message, I do not have a factory roof rack

 

[jjdeneen918]

Mr Toyota still sells the complete sunroof cassette assembly.

I replaced the whole dang thing several years ago to avoid leaks.

I absolutely HATE leaks.

 

[Dr Gil]

Mr Toyota still sells the complete sunroof cassette assembly.

I replaced the whole dang thing several years ago to avoid leaks.

I absolutely HATE leaks.

Thanks. I don't think I need the whole cassette assembly. If anything at all, I feel like a I need a new glass with seal which is NLA.