Disco 2 rain leak at the top corner of driver side

Kaijun · Oct 8, 2020

Recently I got rain leak at the inside top corner of driver side of my D2. By pouring water to the sunroof tray, I made sure drain tubes are clear and also sealed between roof and rail nearby using RTV. I found there is a big gap at the junction between the gutter and the top corner of the driver side of the windscreen, and a small gap at one of passenger side. I am not sure how they are developed, it seems nothing is lost or damaged there. Is this a leak source? how can I fix the gap?, see attached pics.

neilly · Oct 8, 2020

If you do a search there are a few that will include the TSB that shows this exact issue.

Plus the outside edge of the sunroof on the top side where there is a crappy felt seal. It leaks down into the roof as well.

Cheers

Interceptorxj · Oct 8, 2020

These are not usually leak points unless the seam sealer in the joint is cracked. Thes gaps in the windscreen seal are supposed to be there for the water to drain down the outside of the 'A' pillar but on the inside of the 'A' pillar trim.
You won't be able to tell 100% where the leak is unless you remove the roof lining. Did water come out of the sill when you tested the sun roof drains as it is normally the drains that have snapped off in the corners of the sunroof cassette when it leaks that bad?

Andy Warren · Oct 8, 2020

Kaijun said:
Recently I got rain leak at the inside top corner of driver side of my D2. By pouring water to the sunroof tray, I made sure drain tubes are clear and also sealed between roof and rail nearby using RTV. I found there is a big gap at the junction between the gutter and the top corner of the driver side of the windscreen, and a small gap at one of passenger side. I am not sure how they are developed, it seems nothing is lost or damaged there. Is this a leak source? how can I fix the gap?, see attached pics. View attachment 220738 View attachment 220739 View attachment 220740

Hi, I have exactly the same on my D2. The fr. sunroof motor was kaput ( see my previous posts). I removed the headlining & sprayed the roof, water dripped from the motor assy. & in that corner. Removing the s/r & resealing cured the 'motor' leak. I run sealer along the top of the windscreen rubber & sealed the gutter on along the entire drivers side but it still leaked so I stuffed tissue around the roof bar nut(see pic) but that stayed dry so I put tissue along the gutter line inside the car(see pic) & that got damp so I think it's coming through the roof bar gasket into the double skin of the roof/strengthening brkt & running along to that corner. The gaskets arrived today so I'll fit them when the weather holds off & let you know. I've resealed the rear sunroof as well whilst the lining is down.

Kaijun · Oct 10, 2020

I lowered front headliner, poured some water in sunroof tray and felt water from underneath of plastic drain of driver side. I have following questions.
1. Is it possible to fix leak from plastic using silicone in-situ?
2. If not, is it possible to remove sunroof by lowering down front headliner only? I got stuck how to remove A-pillar plastics with small tweeters. I saw youtube or read write-up that it seems to remove rear headliner first, then front headliner

Andy Warren · Oct 10, 2020

Kaijun said:
I lowered front headliner, poured some water in sunroof tray and felt water from underneath of plastic drain of driver side. I have following questions.
1. Is it possible to fix leak from plastic using silicone in-situ?
2. If not, is it possible to remove sunroof by lowering down front headliner only? I got stuck how to remove A-pillar plastics with small tweeters. I saw youtube or read write-up that it seems to remove rear headliner first, then front headliner

Hi,you can I suppose reseal the plastic drip trays with the roof lining down but I would check the pipes aren't blocked first. The inner A pillar trim is held on by three spring clips, when you pull the trim to remove it, pull it evenly/square the clips will either stay on the trim or in the A pillar or both in my case,see pic. Just make sure your happy everything is sealed before refitting the lining,good luck.

Kaijun · Oct 10, 2020

Thanks Andy. It seems my guest is correct after I parked my car with driver side high, no leak happened. I pulled down a bit headlining, those 14 screws are accessible.

Andy Warren · Oct 10, 2020

Kaijun said:
Thanks Andy. It seems my guest is correct after I parked my car with driver side high, no leak happened. I pulled down a bit headlining, those 14 screws are accessible.

No problem, if you are going to remove the whole sunroof under tray & seal them(the plastic corner trays) from the inside just remember it will relieve all the tension on the felt gasket/seal of the glass surround to the roof & these(seals) degrade over time & I wouldn't want you to create another leak so it's up to you if you want to re-seal the glass surround whilst your there(these type of jobs are a pain in the Arsenal but often necessary) , Sikaflex 221 is excellent for this. I took the lining out as I wanted to do both sun roofs the roof rail gaskets & get the head lining re-covered, as I said whatever you decide just double & triple check it's water tight, parking at every angle you can, before reassembly. I'm off to fit my roof bar gaskets, good luck on whatever you decide.

frostythor · Oct 11, 2020

watch this I did to do my headliner

Kaijun · Oct 11, 2020

Thank you for your info again! I lowerd down the front headlining of driver side and checked leak. When I pulled out drain tube, the plastic drain pipe has been snaped off at half. I see ebay has sunroof tray https://www.ebay.co.uk/itm/LAND-ROV...l:Discovery&hash=item366bc7e9bd:g:DGAAAOSw7xl

ffCi4. I

wonder if I can detach the tray only from frame and keep outside frame sealing intact? I resealed the outside frame sealant frame years ago, it seems fine so far. I still have RTV sealant when resealing engine half moon gasket and rear cam, can I use it for sunroof?

frostythor · Oct 11, 2020

yes you can only 14 screw If I remember correctly, I used a tube of black Seal and Adhesive in a gun

Landmark2 · Oct 12, 2020

+1 on above. I also ran sealant around the inside of the frame/roof to be on safe side. Also get some small rubber washers or use sealant on the screws when you re-fit. On mine there were a couple that had gaps around them.
Griff

Hellastony · Oct 14, 2020

Kaijun said:
Recently I got rain leak at the inside top corner of driver side of my D2. By pouring water to the sunroof tray, I made sure drain tubes are clear and also sealed between roof and rail nearby using RTV. I found there is a big gap at the junction between the gutter and the top corner of the driver side of the windscreen, and a small gap at one of passenger side. I am not sure how they are developed, it seems nothing is lost or damaged there. Is this a leak source? how can I fix the gap?, see attached pics. View attachment 220738 View attachment 220739 View attachment 220740

I think you are missing the corner trim that is designed to cover that gap. Dont believe they are still available from LR, but Paul at Discovery2parts (01206 211623, back at work on 19th October) usually has some, also a guy on d2boysclub is I hope going to make some using a 3dprinter. It is numbered 3 on the attached

.

Interceptorxj · Oct 16, 2020

Hellastony said:
I think you are missing the corner trim that is designed to cover that gap.

No he isn't , that is just the gutter trim corner piece which isn't designed to cover the gap and is still in place on both sides in his photos.

Disco 2 rain leak at the top corner of driver side

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