Jeremy Millrood > 1992 Ford Bronco > open folder Firewall Leak Troubleshooting

firewall leak right below the panel that the steering shaft goes through.,
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inside the firewall where the brake booster comes through. looks like this is rusted out. Somehow wa...
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needed to get these wires through the firewall, got a hole saw and opened up the clutch plate blank,...
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pulled the cowl, this is what the trough looks like. I'm not sure where the seams are that go down a...
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this is the trough before I re-sprayed it.
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this small hole, which I'm pretty sure it there to drain water into the trough is underneath the win...
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this is the trough after I sprayed it again with the flex seal material. this initial application di...
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it poured again...
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and there is the water...so either I didn't seal the trough good enough or the leak is coming from s...
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getting ready to replace the windshield for the 2nd time in the last 2 years. this time the guy remo...
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you can see in the upper right hand corner what looks like rust. it's doubtful, but maybe the water ...
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So after all that is still leaked. clearly my problem was not the windshield.
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I used a tube of the Dyantron seam sealer to try and address the leak..my assumption was that it was...
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used what was left of the dynatron grey seam sealer I had and spread it across every possible crease...
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this application of seam sealer was not nearly enough.
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got a as close to the drivers side fender as possible..it was difficult getting my arm in there...
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It poured yesterday and I mean torrential....the only thing the tarp did was keep the water off my b...
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no water under the floor mat.. it looks like I finally solved my firewall leak..
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That was short lived...the next rain the leak was back...
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This is a pic from inside the trough. That lip runs the length of the trough on the firewall, I'll s...
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still wet after the last application of seam sealer.
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got this brushable seam sealer and acid brushes from Eastwood. much cheaper than the stuff in the tu...
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mix it up really good before applying.
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I'm going to show how to remove the cowl to access the trough. First removed the windshield wipers.
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starting from the top, I remove these phillips screws that hold the cowl down. There are 5 of them t...
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you can see all of the holes for the cowl screws in this pic.
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then pop the cover off the antenna mount and remove the 4 screws, pull the antenna up and unplug the...
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remove the antenna cable
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now under the hood. on mine at least, there are 4 additional screws there are two at opposite ends a...
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only thing left is to disconnect the windshield washer hose. I cut mine in the middle and splice it ...
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and you're done..
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this pic is from the inside of the trough facing the firewall. The black stuff at the top is a putty...
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over the years, I'm sure it has started to deteriorate. I'm going to cover the entire area with a lo...
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there you go...
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I went back an covered over this area again.
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Result of a heavy storm last night. Even after applying the seam sealer across the seam on the insid...
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This is a picture from inside of the trough. In addition to applying the seam sealer along the seam ...
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This is the area where the brake booster meets the firewall..I had pulled the booster and sealed it ...
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we had some rain, nothing major, maybe a 15 or 20 minute shower, but the floor board stayed dry.
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got a pretty decent down pour. I'd say 30 to 45 minutes of heavy rain.
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from the inside watching the rain come down...
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floor board is dry.
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Determined to find the leak, I sprayed the hose in the spot I thought it was most likely coming from...
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The water was being sprayed across the top of the brake booster and near the clutch plate cover.
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Water dripping down after spraying around the brake booster.
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top of the brake booster where it meets the firewall. this is the suspect area,
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after applying a copious amount of seam sealer across the top of the brake booster, the leak has gon...
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