It's probably around the pinch weld between the rear glass and the body... this is the most common place for the late model version to leak.

CLICK HERE for a HOW TO

 

Just got my 06 screw back from the dealership after a week to fix the leak. They had to remove the entire dash all the way to the firewall and remove the HVAC box to find that the leak was caused by a body seam which did not get any seam sealer on it from the factory. I bet my truck isn't the only one that got done that way judging from the other leak reports I have been reading. Any way, they sealed the seam from the center of the windshield to the passenger side kick panel and all the way down to the floor. I will leak test it myself tomorrow and see if it is really fixed.

 

Again thank you everyone that replied to this thread i appreciate all your input. Just to make yall aware, my shop was not able to fix the problem the have contacted the regional factory representative in order to pursue the follow ups with lemon law. and I am still awaiting my meeting with them. Thanks everyone Robbie.

 

I don't see anyone checking the rear window. Mine leaked, still, but that is my fault. I removed the rear seat,molding everything to get at window. Get a helper start running the water at the lowest point moving up. Keep a look out around the 10mm nuts take your time it might take awhile to show up. I thought I had it but it started again, I'll be taking it apart this weekend. Let you know how I screwed up.

 

Well the water leak has returned. I will be sending the truck back for the fourth or fifth time now to see if the dealership can fix this. I guess if they don't fix it this time, it will be time to start the lemon law proceedings.

 

Did they check the rear window glass? My 98 had a water leak coming from the back window when it rained. They do not use a lip seal on the back glass. It has threated studs with acorn nuts that seal the the glass in the window frame. They loosen up from vibration and the seal seperates and causes water to get by and leak down the back into the cab. Let me know if that helps. Good luck.

 

I have a 2004 F150 Supercab, 4X4 and the same leak.......passenger side carpet gets wet after a rain.

I did the bubble test, and didn't see an issue with the rear window or 3rd brake assembly. I went to the dealer and asked if there were TSB's on the leak and she told me NO. I have been doing research and found that there are 2 TSB concerning water leaks on the 2004s. The first is the 3rd brake light....so, I bought a new improved 3rd brake light assembly and installed (even though I saw no bubbles).

Last night I found the TSB on the A pillar leak, I will try this when the weather warms. Has anyone performed this yet?? It consists of siliconing the wire run connector from the door to the wire block assembly.

WATER LEAK AT PASSENGER SIDE LOWER TSB 04-21-20
A-PILLAR
FORD:
2004 F-150
ISSUE
Some vehicles may exhibit a water leak through the
bottom cavity of the lower A-Pillar door connector,
on the passenger side of the vehicle. Customer
concern of wet carpet along passenger side kick
panel or water build up along the passenger side
rocker panel.
ACTION
Fill the A-Pillar door connector cavity with
high-grade silicone caulk to eliminate the water
leak. Refer to the following Service Procedure.
SERVICE PROCEDURE
Figure 1 - Article 04-21-20

1. Disconnect door harness from A-Pillar
connector.
2. Remove kick panel trim from passenger side kick panel
3. Loosen central junction box.
4. Remove NVH plug from passenger side kick panel.
5. Unseat A-Pillar door connector from sheet metal.
6. Inject Motorcraft Clear Silicone Rubber (TA-32)TA-32)
or equivalent high-grade silicone caulk into inside bottom cavity of door connector as shown in Figure 1.
7. Let silicone cure as required.
8. Reinstall A-Pillar door connector through sheet metal and ensure it is properly seated.
9. Reinstall NVH plug.
10. Re-secure central junction box.
11. Reinstall kick panel trim.
12. Reconnect door harness to the A-Pillar connector
13. Verify connection with functional check of power window and door lock.


PART NUMBER PART NAME
TA-32 Motorcraft Clear Silicone Rubber
WARRANTY STATUS: Eligible Under Provisions Of
New Vehicle Limited
Warranty Coverage

OPERATION DESCRIPTION TIME
042120A Apply Silicone To Door 0.4 Hr.
Connector
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A005 17
PAGE 2

 

on 97 and early to mid 98 model sliding rear windows the factory used a 3 piece window (you can look at a 97 and a 99 up and see the diffrence look at the top and bottom of the sliding glass part) and on each side of the middle sliding glass the window frame itself leaks, it actually breaks. they have a tsb out on it but only fixed them under warr. no recall so you hafta pay for it, i have seen some fixed with some goop type stuff but ..... your better off to get an updated window(i have seen them break too tho)

 

i did a write up on the other back window leak thread bout how to put in and take out the rear window

 

Hello All,
I just bought my 04 F-150 two days ago and noticed the floor was wet on the passenger side. Its clear water .. not coolant, and seems to be wettest around the kick panel. I am guessing it got there when the make-ready guys gave it a bath before I drove it off the lot. My truck has 25,000 miles on it and is still under warranty. I sure hope that the dealer is able to fix it. I love this truck ! Its the first Ford I have ever owned and the ride, fit, finish and features are far superior to the GM products I have owned in the past ... just my opinion. It was great to be able to find that others have had this same problem and I will certainly be able to approach the service department from a more informed standpoint when I take it in. Thanks to all of you for your posts on this subject, it really helps.

 

I bought my wife an 04 Expedition and it did almost the exact same thing. It would leak, only after a long soaking rain, through the OSH and drip down to the carpet. One time it got so bad that The headliner around the sunroof was soaked as well. The dealer replaced the sunroof and said the drains were clogged as well. I had the problem in December and haven't had a leak since, been too cold to rain, but I'm waiting until spring to see if it still leaks.

 

Okay ... I thought that the leak I had was from water coming into the passenger side after I washed the truck. This apparently isnt the case. I last washed it on Thursday. Since then I haven't used the A/C and only drove for short trips. Monday morning the floor was dry, I ran some errands Monday night in the truck and this morning the floor is wet. No slick feeling or odor to the moisture on the passenger side floor where its getting wet that makes me think it is from the cooling system. The cooling system has pressure. I am dropping it off at the Ford dealership tomorrow morning. I only have 25,000 miles on it and am still under warranty. I wonder if they are going to replace my carpet and/or pad. I will post the findings or lack thereof after I get it back. Any suggestions from anyone as to what to tell them to look for ? Thanks.

 

It took two days but the dealer got the problem fixed. Heres the funny part, they were looking at the back window and the brake light on the top of the cab, then thinking it was related to the box surrounding the a/c condenser even though I told them repeatedly I hadn't run the air for a week. It wasn't until I printed a copy of the service bulletin with the diagram that FORCED347 posted on this thread that they were able to solve the water leak. They had no knowlege of this problem !!! So .... to all of you who posted and especially to you FORCED347, my sincere thanks !

 

so my truck is leaking also... I have an 06 mark lt...I have to bring my truck in this week, again... pass floorboard is wet...they said the prob was fixed of course it wasnt.Should I tell them to rip the truck apart and seal and re-seal everything?

 

No opinions?