All, after spending ages chasing down all the normal leak problems on the Disco 2 and replacing all the various seals I still had a leak into the passenger footwell.
I eventually found the culprit this weekend and I believe it to be a new one, I have an early Td5 - 2000 year.
Inside the engine compartment where the inner wing and bulkhead meet, below the horn and behind the Sound insulation, there is a water trap just below the grommet that has the wiring going into the passenger compartment, Land Rover in their wisdom have put a drain hole in but it is above the low point, water had obviously been trapped here and held in place by the sound insulation.
Having removed various bits and pieces and the sound insulation I found a very large rust patch that was pure rust to the point when prodded it all fell onto the passenger foot well leaving a 50 pence sized whole as well as the bottom of the grommet lip disappearing.
Having rust treated the area I then manufactured a covering plate with the Grommet lip and bonded this in place followed by a heavy cost of under seal which seems to have cured the problem.
The bad news is the drivers sided has an identical design and whilst this is not yet rusted through it can only be a short time, therefore I plan to treat and under seal this side shortly.
Those people with intact vehicles may want to check this area and take precautionary steps, those with mysterious leaks should check this area as well as all the usual leak points.
People buying may want to be advised this is another point to check as you can get your hand down to the area from the engine compartment.
Hope this is of use!
I eventually found the culprit this weekend and I believe it to be a new one, I have an early Td5 - 2000 year.
Inside the engine compartment where the inner wing and bulkhead meet, below the horn and behind the Sound insulation, there is a water trap just below the grommet that has the wiring going into the passenger compartment, Land Rover in their wisdom have put a drain hole in but it is above the low point, water had obviously been trapped here and held in place by the sound insulation.
Having removed various bits and pieces and the sound insulation I found a very large rust patch that was pure rust to the point when prodded it all fell onto the passenger foot well leaving a 50 pence sized whole as well as the bottom of the grommet lip disappearing.
Having rust treated the area I then manufactured a covering plate with the Grommet lip and bonded this in place followed by a heavy cost of under seal which seems to have cured the problem.
The bad news is the drivers sided has an identical design and whilst this is not yet rusted through it can only be a short time, therefore I plan to treat and under seal this side shortly.
Those people with intact vehicles may want to check this area and take precautionary steps, those with mysterious leaks should check this area as well as all the usual leak points.
People buying may want to be advised this is another point to check as you can get your hand down to the area from the engine compartment.
Hope this is of use!
