Body - Various Water Leak Issues
TSB 11-3-1003/15/11
VARIOUS WATER LEAKS
FORD:
2010-2011 Transit Connect
This article supersedes TSB 10-4-9 to update the model years and Service Procedure.
ISSUE
Some 2010-2011 Transit Connect vehicles may exhibit water leaks in various areas of the vehicle.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Water Leak From Center High Mounted Stop Lamp - Built On Or Before 9/27/2009
1. Remove the interior courtesy lamp cover. (Figure 1)
2. Check for trapped lamp wiring or partial installation of the grommet. (Figures 2-3)
3. If wiring is trapped or grommet is not fully installed.
a. Adjust wiring and grommet as necessary. (Figure 4)
b. Perform a leak test.
c. No leaks, return vehicle to customer.
d. If leak persists, go to Step 4.
4. If wiring or grommet positioning are fine and water leak is still present, remove the rear headliner to remove the high mounted stop lamp.
5. Use an alcohol wipe to clean the area around the wiring hole. Apply Motorcraft� Seam Sealer. (Figure 5)
6. Install the high mounted lamp, torque the nuts 22 lb-in (2.5 N.m), attach the wiring connectors.
7. Check the operation of the lamp.
8. Install the rear head liner.
Water Leak From Rear Cargo Doors (Figure 6)
1. If leakage is observed to be around the door striker area, vehicles built on or before 6/28/2010, adjust the strikers so that they move towards the front of the vehicle ensuring that door seals fully to the seals on the body. (Figure 6 Area A)
2. If leakage is observed to be around the door flush-gap area. (Figure 6 Area B and/or C)
a. Check for cracks/holes in the body sealer that is applied between the body panels. Repair the cracks as necessary using Motorcraft� Seam Sealer. (Figure 7)
b. If the water travels under the body weather strip, as shown in Figure 7, remove the weather strip, check the body panel flanges for waviness or irregularities. Repair the flanges as necessary. Apply Motorcraft� Seam Sealer through the channel of the weather strip for better adhesion and reinstall the weather strip.
3. If water leakage is observed only from area C of Figure 6, remove the body weather strip from lower bottom corners. Apply Motorcraft(R) Seam Sealer through the channel of the weather strip, around the lower bottom corners.
Water Leak Into The Footwell Or Heater Blower Case
1. Check for water leaking into the foot well area:
a. If there is evidence of water leaking through dash panel on vehicles built on or before 10/4/2010, the front floor A-pillar opening needs to be sealed. Follow Sealing A-pillar Opening.
b. If there is evidence of water leaking through the floor vents and blower motor case, then the pollen filter case base needs to be sealed, follow Sealing Pollen Filter Case Base.
Sealing A-pillar Opening
1. Check for water leaking into the footwell through the dash panel. If there is evidence of water leaking through the front floor on the driver or passenger side the A-pillar opening needs to be sealed.
2. Remove the upper cowl grill panel and its support on the passenger or driver side where the leak occurred. Refer to Workshop Manual (WSM), Section 501-2 Front End Body Panels.
3. Apply flexible foam inside the bracket mounting area and the windshield, just next to the hood hinge.
4. Apply Motorcraft� Seam Sealer over the foam applied area encircled. (Figure 8)
5. Install the cowl grill panel and support.
6. Dry the carpet and other interior trim as necessary.
Sealing Pollen Filter Case Base
1. Check for water leaking into the foot well through the floor vents. If there is evidence of water leaking through the floor vents and blower motor case, then the pollen filter case base gasket needs to be sealed.
2. Remove upper and lower cowl grill panels, to gain access to the pollen filter. Refer to WSM, Section 501-2 Front End Body Panels.
3. Remove pollen filter case.
4. Apply Motorcraft(R) Seam Sealer on case gasket. (Figure 9)
5. Install pollen filter case and cowl grills. Ensure that the lower cowl grill fully seats on the seal, under the hood.
6. Dry the carpet and other interior trim as necessary
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
110310A 2010 Transit Connect: 0.3 Hr.
Inspect For Trapped Lamp
Wiring Or Partial Installed
Grommet And Repair As
Necessary, And Perform
Leak Test Can Be Claimed
With Operations C, D, E
And F (Do Not Use With
Any Operations Outside Of
This Article)
110310B 2010 Transit Connect: 0.7 Hr.
Inspect For Trapped Lamp
Wiring Or Partial Installed
Grommet And Repair As
Necessary, And Perform
Leak Test. Reseal The
High Mounted Stop Lamp
Can Be Claimed With
Operations C, D, E And F
(Do Not Use With Any
Operations Outside Of This
Article)
110310C 2010 Transit Connect: 0.2 Hr.
Adjust Rear Cargo Door
Stryker Can Be Claimed
With A, Or B, D, And E Or
F (Do Not Use With Any
Operations Outside Of This
Article)
110310D 2010 Transit Connect: 0.4 Hr.
Apply Seam Sealer Onto
The Channel Where
Necessary Can Be
Claimed With A Or B, C
And E Or F (Do Not Use
With Any Operations
Outside Of This Article)
110310E 2010 Transit Connect: 0.6 Hr.
Apply Sealer, Includes
Time To Remove and
Install Cowl Grill, Bracket,
And Remove And Install
Carpet To Dry Can Be
Claimed With A Or B, C,
And D (Do Not Use With
Any Operations Outside Of
This Article)
110310F 2010-2011 Transit 0.9 Hr.
Connect: Seal The Pollen
Filter Case, Apply Sealer
Between The Bracket And
Windshield Includes Time
To Remove and Install
Cowl Grill, Bracket, And
Remove And Install Carpet
To Dry Can Be Claimed
With A, Or B, C And D
(Do Not Use With Any
Operations Outside Of This
Article)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
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