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Water Intrusion Issue - Resolved

Intuit

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#1
2016 Fiesta ST with Sun Roof.
Issue since zero miles.
=======================================
Forum Contributor Posted Comprehensive 32 minute Video:
https://www.fiestastforum.com/threads/water-intrusion-issue-resolved.23553/post-435429
(note: can increase playback to double-speed for a 15/16 minute run)
=============Resolution==================
It is normal for water to bypass the silicon seals around the sun roof. This is by design.
There is a trough system that captures the water, and drains it to all four corners of the vehicle.
The water was NOT making it to the trough system. Instead, some of it was being dumped into the track, used for the sliding sunroof.
There is a "tray" that moves with the sliding glass. This tray is an important part of the trough system.
One side of this mobile tray, had come loose from its "hinge".
So water coming off the glass, misses the tray, trough, and instead lands in the track.
The track then dumps the water directly into the cabin area for the vehicle.

This is not a hard job by any means, and doesn't take a lot of time.
The most exotic tool, is a large Torx bit for the seat belt buckles. Otherwise all normal tools.
You may require a helper when taking down and reinstalling the sunroof frame assembly. (avoid bending/distorting it)
Fold down the rear seats and lean the front back as far as possible.

If you don't fix this, mold can develop. You will see water pooling in the spare tire well, as well as staining at the rear of the headliner.
It is a good idea to replace the light silicon grease lubricant, that has been washed from the track.
Also a good time to use that light silicon grease to lube up the cable system for the roof. (warning: petrolium grease may break down the plastics)
Update re Lubricants, Weather Strip and Fasteners:
Here are high resolution photos (click on link) of the headliner staining and sunroof...
Update re Headliner Stain Removal:
https://1drv.ms/u/s!ABsZJDCN8kMMgaxc
Water Staining 1.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxd
Water Staining 2.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxU
Sunroof 1.jpg
The tray just snaps back into place. I may make a slight modification, to help prevent a repeat; not that I understand what caused it since the module/motor can't be easily operated outside the vehicle.
Update re modifying Sunroof to prevent this problem:
=============Backstory==================
Took it into the dealer. Had one week. Resealed windshield. Replaced sun roof due to unusual noise on tilt. Got it back with some rattles. Different, but sunroof still made an unusual noise on tilt. Inside of windows still fog-up when parked in the sun after rain. Nothing done about clack noise on clutch release. They were nice enough to detail the exterior, but paint was full of swirls and the rear ST emblem knocked loose.

Took it into the dealer. Had two weeks. Smelled like they did a crap-ton of caulking. Got it back with missing paint, unfinished roof rails that were peeling up, a warped rear panel that wouldn't stay in place, additional rattles, a MASSIVE gap between the body and rear hatch. Inside of windows still fog-up when parked in the sun after rain. They also had instructions to determine the cause of a clack noise on clutch release and contact me with diagnosis prior to doing any work. They failed to contact me, unnecessarily replaced the axle shafts, (which made no difference,) and didn't do any post-work testing or alignment. Lock-to-lock turning is now different. Replacement axle shafts are just as rusty/ugly as the original.

So needless to say, I'm taking my own advise and warranty or no warranty, are back to doing my own work. This combined with the ultra-thin minimum possible thickness paint, Ford is unlikely to get my next purchase. There's simply too much competition to put out products and "service" like this.
==============Photos==================
https://1drv.ms/u/s!ABsZJDCN8kMMgaxS
Sunroof 2.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxg
Sunroof Cotterpin Mod.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxe
Sunroof 3.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxW
Water Drip 1.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxV
Water Drip 2.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxT
Missing Part 1.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxb
Missing Paint 1.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxa
Missing Paint 2.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxZ
Roof Rails 1.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxY
Roof Rails 2.jpg
https://1drv.ms/u/s!ABsZJDCN8kMMgaxX
Roof Rails 3.jpg
 


Last edited:
OP
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Thread Starter #5
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Remove through rear hatch. (will require some flexing - but be careful because you can "break" the headliner)
 


OP
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Thread Starter #7
By the way, I reviewed the procedures that Ford has listed for locating the source of a water leak. They suck. Basically they attempt to have the HVAC blower motor, pressurize the cabin while the tech sprays the exterior, looking for bubbles. If this is what they did at the dealer, it's a no wonder they didn't find the source of the issue. I'm also wondering whether that trough, might be knocked out of place during the sunroof initialization procedure.
 


TyphoonFiST

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#9
Best write up I have EVER SEEN! Very informative....Excellent use of diagrams! Good job!



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Business6

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#10
Ugh I have the same friking stains in the headliner.
 


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TyphoonFiST

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#12
I dont .....and I have a sunroof.....at least I think!

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OP
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Thread Starter #13
@TyphoonFiST - Can't take all the credit but thanks.

I think the main lesson from all of this.
DON'T get a sunroof.
LoL I'm FFAAARR too stubborn to listen to this advise. Next one will have a manufacturer installed leak too. Next time I'll just keep it away from the dealer. ;)
 


jmrtsus

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Sunroof.....no leaks. 38K miles. Love my sunroofs. I've had 5 sunroofs, none ever leaked. Keep the seals clean and use a a spray like Armor All to keep them pliable.
 


OP
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Thread Starter #16
It is a good idea to replace the light silicon grease lubricant, that has been washed from the track.
Also a good time to use that light silicon grease to lube up the cable system for the roof. (warning: petrolium grease may break down the plastics)
Krytox Silicon Grease 164-R4906
https://www.amazon.com/s?k=164-r4906

Screw for Roof Panel Frame
W702704-S303
https://www.oemfordpart.com/oem-parts/ford-sunroof-frame-screw-w702704s303

Clips for Paneling
W715667-S439
https://www.fordpartsgiant.com/parts/ford-clip_-w715667-s439.html
(look similar to these https://www.amazon.com/gp/product/B074P2NH57/)

Roof Panel Silicon Glass Weather Strip
YS4Z-6151884-AA
https://www.tascaparts.com/oem-parts/ford-glass-weather-strip-ys4z6151884aa
 


Last edited:
OP
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Thread Starter #17
Put a few these in the your spare tire wheel well.
Spread the rest throughout the vehicle.
*VERY* effective at preventing inside window fogging.
Drying out the cabin air helps deter mold growth. (to a point)

50 Gram [10 Packs] Food Grade Reusable Silica Gel
Desiccant Packets with Indicator Beads
 


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#18
No sunroof on my fist I Hate them and so does my wife our daily comfy car is a 2018 Forester Xt loaded with a massive pano sunroof and we never use it or even have the shade open lol. Sorry to hear about the problems.
 




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