Currently having a bit more condensation than is normal so looking for water ingress points. I haven't actually taken up the floor in the cab yet because it's made of large parts of plastic trim and looks like all the setas need removing to do so but there is clearly water in there somewhere because it's condensating on the front windows (mainly windscreen) and the roof in the back so I need to find out where it's getting in.
So far I've had a look at the following:
Roof rack grommets (No leak found, the grommets are hard plastic though and do rattle a bit but don't seem to be letting water in)
Pollen filter (looks very dry and clean)
Scuttle drain holes:
Is this the drain hole for the scuttle? Drivers side was fairly gunked up with leaves and sludge, passenger side was clear.
Water runs through it fine now:
Drivers side door
The membrane inside was all torn up, found a piece of broken glass in the door which points to the window having been broken at some point which is more than likely the cause of all the tears in the membrane.
Water was getting in and pooling here:
I've temporarily repaired the membrane with duct tape and it no longer leaks. I will order a new one and some kind of sealant as it looks like it's supposed to be stuck on with mastic or something similar.
Passenger side door
Water was getting in through one of the screw holes that hold the interior door handle on so i've covered the holes and all around the plastic inserts in sticky black liquid gasket as that's all I had to hand but I know this stuff does a great job of sealing things so it should work.
Bodywork seam & A/C drain pipe
I did also try to follow this guide which covers the A/C drain hole and some bodywork seam near the scuttle under the bonnet but without taking seats and floor out I can't get to the A/C drain and regarding the bodywork it looks like I'd have to take both windscreen wipers off and all of the scuttle assembly inclusding a part that looks like it's bonded to the windscreen I can't really see exactly what parts of the bodywork they are referring to so for now I've not been able to look at those two areas.
https://ford.oemdtc.com/472/water-leak- ... it-connect
Rear vent flaps
Theres a couple of vent flaps at the very rear of the cargo area, one beneath each light cluster tucked very low down and almost hidden, these are one-way flaps that let the pressure out of the vehicle when you shut doors (pretty sure all vehicles have these) and according to the video below these can let water in. tried soaking them with the hose from the outside but really I need to set the hose up properly underneat the van because lying under the van with hose pointing upwards just leads to you getting really wet real quick but from my limited test I couldn't see any water around the vents on the inside and the whole area in there looked pretty dry and dusty. They are extremely hard to see from the inside so I can't be 100% sure. I do have a cheapo Silverline inspection camera so I will need to revisit this with a proper hose setup underneath the van and the camera inside. The camera isn't very good so not sure it'll be good enough to see water or not. The video below also address the A/C hose and the doors which as above I've done the doors and have not yet done the A/C drain as it looks like a fairly large job.
https://www.youtube.com/watch?v=S3Shj3g ... LeaksFound
Whether or not unblocking the one scuttle drain and fixing the leaking doors has solved my issue is yet to be seen, obviously the doors have been leaking for a while so there will probably be some kind of buildup of water somewhere under the plastic floor so that will keep condensating until its all evaporated so I'm not going to know for a while if what I've done has helped. Until I get time to whip the seats and floor out and dry any residue up i'll just have to keep the heating on (which will no doubt casue more condensation lol) and wait it out and see what happens. I also have a couple of those dehumidifier bag things that are supposed to absorb the moisture so I'm rotating those between the van and a radiator at home so I am at least taking some moisture out of the van proactively.
So, does anyone have any other points of water ingress I can check out? Also when I remove the seats I assume the drives seat will have a sensor in it for the airbag that I'll have to unplug so does anyone know if that will throw a fault code that I will have to get cleared by something more than my cheapo bluetooth code reader? I beleive safety systems usually require a more powerful tool to reset.
I did also see an old post on this forum where someone reckoned that their rubber floor mats were somehow causing a leak and that when they removed them the leak went away. I do have those tray tyoe rubber floor mats and the only logical thing I can think of regarding those is the fact that small amounts of water can pool in them if you get in and out a lot with wet feet rather than get soaked into carpet style mats but in both cases the moisture is still in the van, in once case it's in the carpet and in the other case it's sat on top of the rubber mat, either will condensate back onto the windscreen given the right condiditions so not really sure how the rubber mats themselves could somehow be the cause of a leak and/or condensation?!
