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Firewall Leak Troubleshooting

From 1992 Ford Bronco “Big '92” — documented by Jeremy Millrood.

75 photos
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1992 Ford Bronco - firewall leak right below the panel that the steering shaft goes through., 1992 Ford Bronco - Close-up view of a firewall boot and surrounding metalwork, with bolts circled in red. 1992 Ford Bronco - Engine bay firewall area showing mounting bolts and a section of wiring harness. 1992 Ford Bronco - This image shows a section of a vehicle's engine bay, focusing on wiring and the firewall, with signs of rust and potential water ingress. 1992 Ford Bronco - inside the firewall where the brake booster comes through. looks like this is rusted out. Somehow water much have been coming in.. 1992 Ford Bronco - Close-up of a firewall grommet sealed with red silicone, near a bolt with red paint on its tip. 1992 Ford Bronco - Wiring harness and red sealant are visible on rusty metal in this close-up automotive shot. 1992 Ford Bronco - This image shows a heavily rusted section of a vehicle's firewall with exposed wiring and red sealant applied around a grommet. 1992 Ford Bronco - A bundle of wires passes through a rubber grommet in the firewall, with hoses and other engine components visible. 1992 Ford Bronco - needed to get these wires through the firewall, got a hole saw and opened up the clutch plate blank, the got a piece of pvc and was able to… 1992 Ford Bronco - Close-up view of engine bay components, including hoses and wiring. 1992 Ford Bronco - Corroded window seal showing significant rust and deterioration around the glass edge. 1992 Ford Bronco - A person's reflection is visible in the windshield, with a bird seen in the sky outside. 1992 Ford Bronco - pulled the cowl, this is what the trough looks like. I'm not sure where the seams are that go down along the firewall, but I had sprayed so… 1992 Ford Bronco - this is the trough before I re-sprayed it. 1992 Ford Bronco - this small hole, which I'm pretty sure it there to drain water into the trough is underneath the windshield trim..it was a little clogged u… 1992 Ford Bronco - Engine bay seam with visible dirt and rust accumulation. 1992 Ford Bronco - this is the trough after I sprayed it again with the flex seal material. this initial application didn't do anything. if you're going to us… 1992 Ford Bronco - it poured again... 1992 Ford Bronco - and there is the water...so either I didn't seal the trough good enough or the leak is coming from somewhere else. 1992 Ford Bronco - getting ready to replace the windshield for the 2nd time in the last 2 years. this time the guy removed all of the old sealant from the fra… 1992 Ford Bronco - you can see in the upper right hand corner what looks like rust. it's doubtful, but maybe the water was getting in through there. 1992 Ford Bronco - So after all that is still leaked. clearly my problem was not the windshield. 1992 Ford Bronco - I used a tube of the Dyantron seam sealer to try and address the leak..my assumption was that it was still coming from the trough..even usi… 1992 Ford Bronco - used what was left of the dynatron grey seam sealer I had and spread it across every possible crease/crack I could reach in the trough.. 1992 Ford Bronco - this application of seam sealer was not nearly enough. 1992 Ford Bronco - got a as close to the drivers side fender as possible..it was difficult getting my arm in there... 1992 Ford Bronco - It poured yesterday and I mean torrential....the only thing the tarp did was keep the water off my back seat. there was a pool of water in… 1992 Ford Bronco - no water under the floor mat.. it looks like I finally solved my firewall leak.. 1992 Ford Bronco - That was short lived...the next rain the leak was back... 1992 Ford Bronco - This is a pic from inside the trough. That lip runs the length of the trough on the firewall, I'll seal that up with the seam sealer. 1992 Ford Bronco - This image shows a corroded metal surface with visible rust and a textured finish, along with website text. 1992 Ford Bronco - Close-up of a rusted metal panel, likely from a vehicle's undercarriage or firewall. 1992 Ford Bronco - Undercarriage shows signs of rust and water accumulation, potentially indicating a leak. 1992 Ford Bronco - still wet after the last application of seam sealer. 1992 Ford Bronco - got this brushable seam sealer and acid brushes from Eastwood. much cheaper than the stuff in the tubes and there is a lot more of it. the… 1992 Ford Bronco - mix it up really good before applying. 1992 Ford Bronco - I'm going to show how to remove the cowl to access the trough. First removed the windshield wipers. 1992 Ford Bronco - starting from the top, I remove these phillips screws that hold the cowl down. There are 5 of them that run the length of the cowl. 1992 Ford Bronco - you can see all of the holes for the cowl screws in this pic. 1992 Ford Bronco - then pop the cover off the antenna mount and remove the 4 screws, pull the antenna up and unplug the cable. It may take a bit of effort. 1992 Ford Bronco - remove the antenna cable 1992 Ford Bronco - now under the hood. on mine at least, there are 4 additional screws there are two at opposite ends and two in the middle that hold the A/C… 1992 Ford Bronco - Close-up view of the engine bay of a white vehicle, highlighting various mechanical components and signs of wear. 1992 Ford Bronco - This image shows a section of a vehicle's engine bay, focusing on various hoses and wiring harnesses. 1992 Ford Bronco - only thing left is to disconnect the windshield washer hose. I cut mine in the middle and splice it with a vacuum connector to make it easi… 1992 Ford Bronco - Close-up view of the windshield cowl and wiper area on a white vehicle, showing the perforated vent cover. 1992 Ford Bronco - The 1992 Ford Bronco's windshield cowl shows signs of age and potential water intrusion points. 1992 Ford Bronco - and you're done.. 1992 Ford Bronco - this pic is from the inside of the trough facing the firewall. The black stuff at the top is a putty like substance that was put there from… 1992 Ford Bronco - over the years, I'm sure it has started to deteriorate. I'm going to cover the entire area with a load of seam sealer. 1992 Ford Bronco - there you go... 1992 Ford Bronco - Close-up view of grey sealant or undercoating, showing texture and application detail. 1992 Ford Bronco - Thick underbody sealant is visible in this close-up shot. 1992 Ford Bronco - This image shows a section of underbody sealant, possibly from a vehicle's firewall area, with visible rust. 1992 Ford Bronco - Close-up of grey sealant on a rusty metal surface, likely part of a vehicle's undercarriage or engine bay. 1992 Ford Bronco - I went back an covered over this area again. 1992 Ford Bronco - Result of a heavy storm last night. Even after applying the seam sealer across the seam on the inside of the trough I still had water on th… 1992 Ford Bronco - This is a picture from inside of the trough. In addition to applying the seam sealer along the seam at the top, I ran another coating acros… 1992 Ford Bronco - This is the area where the brake booster meets the firewall..I had pulled the booster and sealed it with RTV a while ago, but I found areas… 1992 Ford Bronco - we had some rain, nothing major, maybe a 15 or 20 minute shower, but the floor board stayed dry. 1992 Ford Bronco - The dirty interior floor of a vehicle shows pedals and wiring, with a visible brake release lever. 1992 Ford Bronco - got a pretty decent down pour. I'd say 30 to 45 minutes of heavy rain. 1992 Ford Bronco - from the inside watching the rain come down... 1992 Ford Bronco - floor board is dry. 1992 Ford Bronco - Determined to find the leak, I sprayed the hose in the spot I thought it was most likely coming from. 1992 Ford Bronco - The water was being sprayed across the top of the brake booster and near the clutch plate cover. 1992 Ford Bronco - This image shows a damaged seam sealant on a vehicle's firewall, possibly indicating a leak point. 1992 Ford Bronco - Water dripping down after spraying around the brake booster. 1992 Ford Bronco - Close-up of a firewall grommet, sealed with sealant, with visible wiring and a hose. 1992 Ford Bronco - Close-up of a rusted metal seam with sealant and red fluid, possibly indicating a leak. 1992 Ford Bronco - top of the brake booster where it meets the firewall. this is the suspect area, 1992 Ford Bronco - after applying a copious amount of seam sealer across the top of the brake booster, the leak has gone away..at some point down the road I'l… 1992 Ford Bronco - This image shows a severely corroded metal component, likely part of a vehicle's undercarriage or firewall. 1992 Ford Bronco - Oily residue is visible on the firewall, indicating a potential leak.