Hi guys! I have a serious problem. I have a 2005 FX4 extended cab truck. I backed out of my driveway the other day and water sloshed onto my left foot!!! I thought the replacement windshield had a leak so I took it back to them. They pulled up the kick panels next to the seat that cover the wire routing channels and both sides were about to overflow. They air/foam tested the windshield to confirm there were no leaks. To be sure, they took it next door to an auto top company who puts in sunroofs and convertible tops. They found 2 body seams that "need to be fixed" and that the water was coming in from around the door checks on both sides. They couldn't guarantee that it would stop the problem. The body seam was fixed ($200 to troubleshoot and repair seams) but truck is still leaking. I'm the original owner and truck hasn't been wrecked. I took it to Ford to let them do a water leak test on it. They found a windsheild leak and we called the glass company back out to show them. They re-applied eurothane and said that should fix it. They also paid the $88 diagnostic fee that we would have been charged by Ford. I called the glass company and told them that I wasn't happy with that. The globs of eurothane was pitiful looking. I made them install a new windsheild. They still insist that we have a leak and are blaming it on the door checks, on both sides. Ford says they've never seen this happen before, but aren't saying it can't. It goes back to Ford Tuesday for another leak check. (the glass company is paying to have the carpet cleaned and I want to stop the leaks before I waste this chance to get my carpet done) This is getting to be so aggrevating. On top of that, today the passenger side turn signal isn't working. When you turn the signal on, the inside indicator arrow lights up solid green and the lights on the outside of the truck stay lit but don't blink. I checked the fuses and all bulbs and everything is good. I replace the relay under the steering column and it still won't work. If the truck isn't running the hazzards will flash. If it's running or if the key is in the accessory position the hazzards will come on, but won't flash. Also, when the truck is off and the hazzards are flashing, there is a LOUD clicking noise coming from under the hood. I think we pinpointed it to a gold switch (?) on top of the intake at the top of the motor...not sure what it's connected to. I've included pictures of both the door check that they claim needs to be replaced and whatever it is that's making that clicking noise.

 

you probably have corrosion on the fuse box from water on it...mine did the same thing, all electrical functions were screwed up when I had water in my rockers and it got on the fusebox, its about 300 bones to put a new one in

 

Thought I'd update. I have this post on 2 other F150 forums. Here is one of the answers I got. Hope this helps with anyone else having problems.



Thanks for the info. We did the 3rd brakelight check that you suggested, although it supposedly had already been checked and ruled out. We had a fair amount of rain here, so the top of the cab was already wet, but just to be sure I wet it again. I did not have any water blowing back onto me, so I guess that can be ruled out for sure as well. Thanks again, it's going back to Ford tomorrow and I will update when we finally get this resolved.

 

Hey guys, another update. The glass company installed a new windshield, refunded our $200 that the auto top place charged us and gave us a voucher to have the carpet and padding pulled out and cleaned. They still insisted that the leak was coming from the door checks. We took the truck to Ford and had them put the door checks on after they couldn't find a windshield leak. They ended up having to replace some module to fix the issue with the turn signals/flashers. So, $600 later here's where we are: the night we picked up the truck the ABS light mysteriously come on, but not consistently. We've found that it WILL come on when you turn on the headlights. If you crank the truck and don't turn the headlights on, it won't come on. We called Ford back and they said it's either a sensor going bad or could possibly be the processor having problems which is where the signal/flasher module plugged in. (This was replaced last summer because of issues with the alternator) They told us if that was the problem, it's covered under warranty until 80,000 miles. Keep your fingers crossed that that's the problem. We had rain move through today, so last night we pulled back the carpet and put paper towels in the channels by the kick panels. Drivers side towel was bone dry, passenger side still had water, but not nearly what it did have. Soooo, next week it goes BACK to Ford AGAIN to see about the ABS light and the now smaller leak....ARGHHHHH!!!!!!

 

I have an 04 screw and I constantly had water on the left side next to the fuse box and it would fill up the channel with the harnesses. I took it back to Ford 4 time before they realized it was the third brake light leaking. They blamed the door seals, the weep holes on the bottom of the doors and the hinge holes in the cab body. maybe this will help.

 

apparently its a huge well known problem.

this is why i tend to wait until a new style has been out a few years.. gives em time to work the bugs out... then time to test the new fixes for new bugs.

 

Sorry for the late update, we FINALLy got the problem fixed. Turned out to indeed be the check strap holes around the door hinges. $400 repair and not a leak since!!!