Sunroof leak that won't stop...

[mjl132]

I have a 1995 80 and have experienced intermittent sunroof leaks, like I'm sure all have, but lately I'm about to go nuts trying to track down the latest and stop it. I have read every thread I can find on sunroofs and fixing leaks; I have cleaned the drains up top, cleaned the slits on the bottom, pulled the bottom drain plugs, and cleaned the channels around the sunroof, all to no avail.

So tonight while it's dumping rain I parked outside to see what happened and it's still leaking. Just on the passenger side and just in the right foot well where the drain plug is located under the wiring on the near the door. It appears to be leaking from sunroof, running along the rubber grommet on the door jam, and dumping into the footwell. When I pour water into the sunroof drains, I can remove the grab handle on the passenger side and lower the head liner ever so slightly and watch the water back up in the channel designed to stop water and spill onto the headliner, run toward the door, catch the rubber on the door will/jam, and go into the floor and pool on top of the drain.

I hope this all makes sense and someone can help me. If its vague, I can try to post some pictures of where the water is pooling and where its running along. I am desperate here, I'm sick of a wet passenger floor board.

 

[abrumley]

I am sure some people will think this suggestion is nuts but I blew my lines out from the top down with some vacuum line connected to an air gun on my compressor. It shot a bunch of crap out and hasn't leaked since

 

[greentruck]

In some cases I've read, the clip that holds the drain tube to the drain has either come loose (perhaps due to vigorous previous drain opening) or, in a few cases, was perhaps improperly installed at the factory. This would cause a leak similar to what you describe.

 

[Kernal]

Do not use compressed air on the lines, a few people have blown the plastic drain line off the drain pan doing that. Is the water backing up and then overflowing the drain pan? How did you clean the drain lines?

 

[2fpower]

There are four drain lines, one at each corner of the window unit. The front two you can get to, the rear two you have to pull down the headliner. Are you cleaning out both front ones?

I would recommend pulling down the headliner and getting a good look at the issue.

 

[mjl132]

In some cases I've read, the clip that holds the drain tube to the drain has either come loose (perhaps due to vigorous previous drain opening) or, in a few cases, was perhaps improperly installed at the factory. This would cause a leak similar to what you describe.

The front two clips are good and they are there. I may have to drop the headliner.

 

[mjl132]

Do not use compressed air on the lines, a few people have blown the plastic drain line off the drain pan doing that. Is the water backing up and then overflowing the drain pan? How did you clean the drain lines?

I ran weed eater line through the front two holes to clean them. When I pour a cup of water in them they drain pretty well. When I drop the head liner just a little to look it almost looks like water is overflowing out of the pan, but only on the passenger side, then running onto the headliner and down into the floor board.

 

[bobthebuilder]

I will be doing this soon on my 93. Can I retrofit a newer headliner into my truck in the event that I ruin my OE headliner?

 

[thatcabledude]

I will be doing this soon on my 93. Can I retrofit a newer headliner into my truck in the event that I ruin my OE headliner?

I would love to do the same. IDK if anyone has actually gone through with that swap yet. One thing to consider is that you will also need to also swap in the newer pillar trim pieces too. I'm also thinking maybe the front seat belts too since the newer models are adjustable height.


OP.... Just so I am clear, when you say ''pulled the bottom drain plugs'' which ones are you refering too? The ones in the floorboard or the ones on the bottom of the rockers? I have abandoned the drain slits in the rockers and just left the rocker "drain plugs" out for better/faster drainage.

 

[MrOffshore]

As long as you take your time and are careful, you should be able to pull your headliner down without too much trouble...it's also a great time to clean it...but be careful as it's easy fuzzball them up if you scrub them at all. I suggest (sorry for being off topic for the moment) spraying a quality carpet cleaner on the headliner, let it soak in...MIST it with a hose and use a wet/dry vacuum to suck the water back out...repeat as necessary and make the last few mists with water only making certain to pull all the cleaning solution out of the headliner. I do this with the headliner sitting on it's side against a wall. If you get any fuzzy spots either from vacuuming it or if it required some light scrubbing you can shave the fuzzies down easily with a beard trimmer. It should look as good as new. Don't forget the headliner on the sunroof and the side panels (not easy to get off, might be easier to do in place).

I hit all four of my drain lines with compressed air...light loads, not full blast. I noticed that the plastic connectors at the pan where the drain tubes connect are very weak...mine were even ground on a bit from the factory...these could be cracked and leaking on your truck. Don't panic, a good silicone caulk can fix it good as new. I went so far as to actually pull my drain tubes out and make CERTAIN they were cleared. The bad news...with all of my work my sunroof still lets' water into the body of the truck...but at least it's not still coming inside the cabin. If I had the time and energy I would weld the poorly designed sunroof shut permanently. This truck should never have come with a sunroof.

Good luck, I feel your pain!!

 

[mjl132]

I pulled the plugs in the rocker panels so it would flow more freely out. I'm going to drop the head liner I guess. I want to take a piece of steel and just weld it over the damn sunroof and tape a picture of the sky on the inside so when the sunroof panel inside is pulled open you see the picture of the sun.

 

[thatcabledude]

The bad news...with all of my work my sunroof still lets' water into the body of the truck...but at least it's not still coming inside the cabin.

Where is it leaking into now?

 

[2fpower]

I have an extra headliner if anyone needs one. tan in color. Price is free to good home. Location KC.

 

[bobthebuilder]

Might take you up on that!

 

[mjl132]

I have an extra headliner if anyone needs one. tan in color. Price is free to good home. Location KC.

I need a clean one. Mine is bad from the leak.

 

[Kernal]

mkl 132: Did you remove the plugs on the inside of the rocker panel or the plugs on the bottom of the floor in the wheel wells? The drain lines drop into the rocker panels but just dangle inside, they aren't attached to anything. In the photo I pulled the lower end of the drain hose out of the rocker panel cavity. Some had good luck by wrapping a bicycle inner tube (one layer thick) around the sunroof (glass) gasket to make it seal better, others took thin speaker wire and stuffed it under the gasket.

https://forum.ih8mud.com/80-series-tech/235129-bicycle-tube-sunroof-fix-wind-noise-gone.html

You may have already found these:

https://forum.ih8mud.com/80-series-tech/260221-how-sun-roof-repair.html

https://forum.ih8mud.com/80-series-tech/367458-sunroof-still-leaking-wtf-am-i-missing.html

https://forum.ih8mud.com/80-series-tech/359178-leaking-sunroof-major-frustration.html

https://forum.ih8mud.com/80-series-tech/281666-2-minute-fix-sunroof-noise.html

 

[2fpower]

Pic of headlinee

 

[eplazajennings]

Silicone Time

I pulled the plugs in the rocker panels so it would flow more freely out. I'm going to drop the head liner I guess. I want to take a piece of steel and just weld it over the damn sunroof and tape a picture of the sky on the inside so when the sunroof panel inside is pulled open you see the picture of the sun.

I have been fighting this fight for a while as well and am considering just siliconing the entire thing shut for good. I just cleaned mine out again really well so hopefully this will last a year or so. It would look silly in my case to have a sun roof hatch on my roof rack without an operating sun roof but I'm getting awful tired of explaining the musty smell of my truck.

 

[breathed]

Have you examined the cable dust covers? They often warp with time/heat and won't direct water to the front drain tubes properly.

 

[Godwin]

I have been fighting this fight for a while as well and am considering just siliconing the entire thing shut for good.

I'm about to do this. For over a year have had serious leakage fore and aft on the driver's side and we never use the sunroof. My solution will be to stop it at the source.