Leaking from somewhere, out of ideas

[airbox]

1998 Montero (2.5gen). I bought this car in September and realized about a few weeks later that I have a serious leak coming from the top corner of the windshield area. Normally I figure it would be the windshield, but I have taken it back to the glass installers and had it reset three times. They did a pretty good job gooping it up with sealant, so they and I am convinced it isn't the windshield. I noticed then it was coming in through the tack welded pieces of sheet metal above where the windshield sits, and noticed some water sitting in the hole area where the passenger side sun visor mounts. Seems like the water is getting in through some pieces of sheet metal. The car is rust free (believe it or not for an island car) and doesn't have any gaps where the door closes. The water enjoys running down the right side of the firewall behind the ECU and onto the floor and pooling there making the carpet smell lovely. I checked the sunroof and the rubber drain hose that goes to the fender and its fine and not leaky. Even the fluffy insulation is not wet, so it has to be coming from a welded area. The only thing i can think of is maybe it is getting into the sheet metal in the gutters, but that is all i have. I'm at wits end and it is eating away at my humanity and every time it rains, a piece of who I am dies a little. Anyone have a leak similar to this? Please help before I sillycone every nook and cranny!

I don't have any photo editing software on my computer to show precisely, but this is the area it is coming through. In between the welds about an inch or two from the top of the windshield...


This is where the sun visor mounts, and the water sits in here too.


The floor where the water pools (in the corner.)


Dry as a bone in this area.

 

[evol911]

Since you have everything torn apart, get the hose out and run it over the top of the truck.

 

[Jay Ayala]

My initial thought was drain tube related. But that is really rare.

 

[The Rover Shop]

If you have roof rails that protrude through the roof make sure they are sealed..

 

[airbox]

Thanks for responding guys. I have used the hose over the top of the roof, that's where I've noticed it coming through the welds. And it does not have factory roof rails. Just gutters. I packed some silicone into the groove where the trim covers the gutters (without compromising the gutter's purpose). Once it dries I'll try again.

 

[czd3my]

I had a 96 that leaked in the same area except on the drivers side. Mine would leak during a sprinkle one time and not during a downpour the next. Drove me crazy! I even went so far as to buy one of those little inspection cameras and drilled a hole in the "A" pillar trying to find it with a lawn sprinkler running. I'd warn against silicone as it will hold moisture and cause rust. Try using urethane rubber either in caulking tubes or the stuff in ribbons. I finally concluded mine was finding a way in around the windshield sealant and "wicking" in between the pinch weld. Waters surface tension can make it seem to climb. I wish you luck! If you need to get that gutter trim off try using and old can opener with one rounded and one pointed end. Wrap the rounded end in tape and work slowly from one end of the trim. I feel your pain! I worked for a year trying to find mine and never had carpet in it for fear the new windshield would leak too.

 

[airbox]

I had a 96 that leaked in the same area except on the drivers side. Mine would leak during a sprinkle one time and not during a downpour the next. Drove me crazy! I even went so far as to buy one of those little inspection cameras and drilled a hole in the "A" pillar trying to find it with a lawn sprinkler running. I'd warn against silicone as it will hold moisture and cause rust. Try using urethane rubber either in caulking tubes or the stuff in ribbons. I finally concluded mine was finding a way in around the windshield sealant and "wicking" in between the pinch weld. Waters surface tension can make it seem to climb. I wish you luck! If you need to get that gutter trim off try using and old can opener with one rounded and one pointed end. Wrap the rounded end in tape and work slowly from one end of the trim. I feel your pain! I worked for a year trying to find mine and never had carpet in it for fear the new windshield would leak too.

Thanks czd3my, took off the trim like you said and it is coming from the pinch welds underneath. Ill take it to a body shop and see what they can do.