Failure of One Drain Tube in Moon Roof Drainage System

[wharrell]

Big problem on my hands and first with a sun/moon roof

Several weeks back, I noticed purple staining on my headliner right at the left driver front pillar area, 3"x4" area. It was not damp when I first noticed it but obviously something had occurred as the headliner fabric was stained purple where the insultation/backing had gotten wet and soaked the headliner.

Then last Saturday in a good rain on the highway, the area was sopping wet, checked everything but could not say for sure where it was getting in.

Finally this afternoon, I had some time off to do some water testing. I did the following:

1. Located the drain holes in the moon roof area that are designed to collect and drain any water that should get in. Inspected the area and it is free from any trash, etc.

2. I slowly poured around 3 oz of water into the recessed area in the front left area to allow it drain into the drain hole. Now the bad news.

3. I could feel water around the interior rubber gasket near the top of the front pillar, so that is how the headliner is getting wet.

4. Even worse, water then started dripping out from underneath the dash through the electrical systems area to the lower left of the steering column. Water puddled on the Weathertech hard shell mat liners. No water whatsoever drained outside of the truck. The water ran fine into the drainage hole with no backup, so it appears the darn drain tubes are just completely unattached somewhere but is impossible to see without ripping open the head liner.

To come think of it, water was there last Saturday also but thought nothing of it at the time as it is normal for those shell mat liners to be wet from your boots getting in or out of the truck.

Questions:

1. Does anyone know exactly where the bottom of those drain tubes are where the water should drain out to the exterior of the truck? You would think those tubes would be one solid piece, but apparently they have joints somewhere.

2. I am luckily still under my 36/36k warranty, so I am warranty covered but this will require a replacement of the head liner. How the heck do they get that shell headliner into the interior of the truck on a replacement? Is the windshield removed? It appears to be a type of formed shell liner with the tan fabric attached. (I did read that the Extended Service Warranty excludes water leaks after the initial 36/36 warranty)

Either way, once the dealership can get on it, I think it is best not to replace the headliner until after the fix attempt has been tested through several rains and sitting out in the rain to risk having to go through a headliner repair a second time.

Has anyone had a similar problem and is anyone aware of a Technical Service Bulletin on this issue on a 2008 F250. My experience is the dealership rarely offers up information on a TSB and that I have to go into the service department with one in hand

[senix]

I would take it in and have them just do it. Windshield does not come out for this. Big reason I don't have sunroof's

[smotrs]

I'd second taking it the dealer as well. The only reason I would bother to tackle something like that is if the warranty was up. But yours isn't so make them fix it.

Stick to your guns, have them check for rusting as well, maybe bring you back to inspect various stages of the process so you can see for yourself. Also have them take notes, no telling what could happen to the electrical system down the road as a result of water being there. And with our luck, something would happen just after the warranty expired.

Definitely sucks dude, hope you get it fixed.

[rock_doctor]

Let us know what they come up with, i also have the moon roof.

[smotrs]

Originally Posted by rock_doctor

Let us know what they come up with, i also have the moon roof.

Same here, that's another reason I'm curious as to what they do or don't do.

[Stalwart]

I hate sunroofs but mine came with one I occasionally use some REALLY big weed wacker line, the square stuff, and poke it down the drains followed by a blast of compressed air just to keep 'em clean.

[wharrell]

Does anyone know if the drain tube is in one solid piece from the moon roof to the exteriior of the truck with any junctions, Ts or other connections?

Reason I ask is that mine is not leaking right at the moon roof, it is leaking at the top of the left pillar. If it was plugged up, it would backup to the moorn roof. After I performed my leak test, I did run weed wacker line down the tube with no success in clearing anything.

It will be late in week before dealer can get on it and then likely out of vehicle for a several weeks per dealer while diagnosed, parts orders and repairs made.

[Jus Cruisin]

Originally Posted by wharrell

Does anyone know if the drain tube is in one solid piece from the moon roof to the exteriior of the truck with any junctions, Ts or other connections?

Reason I ask is that mine is not leaking right at the moon roof, it is leaking at the top of the left pillar. If it was plugged up, it would backup to the moorn roof. After I performed my leak test, I did run weed wacker line down the tube with no success in clearing anything.

It will be late in week before dealer can get on it and then likely out of vehicle for a several weeks per dealer while diagnosed, parts orders and repairs made.

Should be one piece. Might find the drain tube might have gotten pinched/cut and causing a leak. A good water leak guy should be able to diag and fix in one day. There is a great water leak company in central Florida. That is all he does. There should be one in your area that is Ford approved that stops by dealers on a weekly basis.