frostythor · Jun 17, 2021

Last year with my headliner soaked and caving in it was time to do something about it so I removed it and the sunroofs , fixed the both, resealed, recovered the headliner , nice and dry now…

But my carpets still soaked…. So yesterday, out came the driver seat then the carpet

I took off the external “A “post cover and removed the wipers then removed the windscreen lower Molding-Plenum Air Intake extension, that’s the big black cover held in place by the wiper blade spindles

I removed the “A” post outer cover by drill a small hole in the 3 plugs then screwed in a small screw and just pulled them out, saving the need to replace them

After a good inspection I found the wiper motor mounting plate was parting from the seal as it was clear the lower seal on the window was not working well and water was passing it, causing it to rust so I took it all out and also found that the wiper motor was loose on the plate and that explains why my wipers have always been to noisy

So I cleaned it all a coat of zinc, a liberal coating of sealer on both sided of the rubber seal and replaced it, all good so far, then …

The actual seal was split, and after a searching on the internet found out they are obsolete and now no one has any, so lots of a sealer later, it hope full stuck in place with a nice thin bead between it and the screen, I then did the top of the “A” post, and the bottom of the “A” post cover to try and keep it off the carpets, I have put the seat back but as it due to rain, so I’m leaving the carpet out to see if anymore water is getting in finger crossed

There is one more item related in my quest to find a replacement seal I came across a company that specializes in car seals, on their web page they had a few that at a push may have fitted an been a replacement for the ripped seal, I called them and they returned my call, and asked what the seal was for and that they would send me a sample to see if any of their current stock would be suitable

They requested a measurement of the seal so I sent them a CAD drawing of the seal in the hope they will find a good match of even remanufacture the seal….. I will post any feed back

Andy Warren · Jun 17, 2021

frostythor said:
Last year with my headliner soaked and caving in it was time to do something about it so I removed it and the sunroofs , fixed the both, resealed, recovered the headliner , nice and dry now…

But my carpets still soaked…. So yesterday, out came the driver seat then the carpet

I took off the external “A “post cover and removed the wipers then removed the windscreen lower Molding-Plenum Air Intake extension, that’s the big black cover held in place by the wiper blade spindles

View attachment 240644

View attachment 240645

I removed the “A” post outer cover by drill a small hole in the 3 plugs then screwed in a small screw and just pulled them out, saving the need to replace them
View attachment 240647

After a good inspection I found the wiper motor mounting plate was parting from the seal as it was clear the lower seal on the window was not working well and water was passing it, causing it to rust so I took it all out and also found that the wiper motor was loose on the plate and that explains why my wipers have always been to noisy
View attachment 240648

View attachment 240649

So I cleaned it all a coat of zinc, a liberal coating of sealer on both sided of the rubber seal and replaced it, all good so far, then …

View attachment 240650

The actual seal was split, and after a searching on the internet found out they are obsolete and now no one has any, so lots of a sealer later, it hope full stuck in place with a nice thin bead between it and the screen, I then did the top of the “A” post, and the bottom of the “A” post cover to try and keep it off the carpets, I have put the seat back but as it due to rain, so I’m leaving the carpet out to see if anymore water is getting in finger crossed

There is one more item related in my quest to find a replacement seal I came across a company that specializes in car seals, on their web page they had a few that at a push may have fitted an been a replacement for the ripped seal, I called them and they returned my call, and asked what the seal was for and that they would send me a sample to see if any of their current stock would be suitable

They requested a measurement of the seal so I sent them a CAD drawing of the seal in the hope they will find a good match of even remanufacture the seal….. I will post any feed back

Hi, was the water dripping onto the carpet pile or getting wet between the floor pan & foam backing ?

frostythor · Jun 17, 2021

I still have the carpet out , and we have just had a lot of rain there is still a small amout getting in so in the morning I will be sealing the seal under the plastic lower Molding-Plenum Air Intake , as I can see a small leak there and as I have seal the complete screen and it has water in after the rain, the next one is the roof gutter, I have not scrapped it out and replaced the orininal seam sealer

Andy Warren · Jun 17, 2021

frostythor said:
I still have the carpet out , and we have just had alot of rain there is still a small amout getting in so in the morning I will be sealing the seal under the plastic lower Molding-Plenum Air Intake , as I can see a small leak there and as I have seal the complete screen and it has water in after the rain, the next one is the roof gutter, I have not scrapped it out and replaced the orininal seam sealer

Yeah the heater intake is a definite place to leak, (I even put Sikaflex 221 on the threads of the bolts holding it in just in case) it caused water to drip onto the carpet off the fan casing inside. The roof gutters normally only cause the roof lining to get wet, the water was getting in above the rear passenger door (through the putty LR put in the gutter) & traveling along the guttering on the inside of the car & ending up, either end of the roof, depending whether the car was facing up or down hill, good old Captain Tolley's crack sealer cured that.

Spong · Jun 19, 2021

Andy Warren said:
Yeah the heater intake is a definite place to leak, (I even put Sikaflex 221 on the threads of the bolts holding it in just in case) it caused water to drip onto the carpet off the fan casing inside

Ah! This is the problem I have. I couldn't trace the drip beyond the hater fan motor, so I wasn't sure if it was a seal around the windscreen or coming in through the heater intake. Is the lower moulding difficult to get off?

Andy Warren · Jun 19, 2021

Spong said:
Ah! This is the problem I have. I couldn't trace the drip beyond the hater fan motor, so I wasn't sure if it was a seal around the windscreen or coming in through the heater intake. Is the lower moulding difficult to get off?

Taking the scuttle panel off isn't too bad but it is a brittle I managed to crack mine until I loosened the bonnet bolts & moved it slightly so I could wiggle the panel out. Sealing it is just a case of running Sikaflex 221 or similar round it. You'll see from my pics. the water running in before & how warped the heater intake was.

frostythor · Jun 19, 2021

Well after replacing every thing , I still had a bit of water coming in so I have taken it all off again, and will start again later to day as I have just completes replacing my rear ACE mounting bush but thats another post to come

will update the carpert when it al done again

frostythor · Jun 19, 2021

Well I think I have found were the water is getting in, I thought it was here on the heated screen cable as the grommet was a very loose fit on the cable and not a tight fit in the hole, so I was cleaning out the seam ready to cover it in fresh seam sealer,....

But when I got to the lower right hand side below the wind screen I found this ...

so I think it needs a bit more than seam sealer ..

Spong · Jun 19, 2021

Andy Warren said:
Taking the scuttle panel off isn't too bad but it is a brittle I managed to crack mine until I loosened the bonnet bolts & moved it slightly so I could wiggle the panel out. Sealing it is just a case of running Sikaflex 221 or similar round it. You'll see from my pics. the water running in before & how warped the heater intake was.

Thanks, that's very helpful. Presumably there's a foam seal between the bodywork and the flange of the duct? Odd that the lower two bolts are rusty, while the top two aren't - do you think that water has been pooling there and running in?

Andy Warren · Jun 19, 2021

Spong said:
Thanks, that's very helpful. Presumably there's a foam seal between the bodywork and the flange of the duct? Odd that the lower two bolts are rusty, while the top two aren't - do you think that water has been pooling there and running in?

Yeah, there is (or was) a foam seal round the intake but like the sunroofs seals they just disintegrate over time. I don't think the water can pool that high unless the drain holes are blocked at each end of the bulkhead but that area was full of old leaves/silt when I got it so who knows & I've since changed the bolts for stainless.

westone · Jun 19, 2021

frostythor said:
Last year with my headliner soaked and caving in it was time to do something about it so I removed it and the sunroofs , fixed the both, resealed, recovered the headliner , nice and dry now…

But my carpets still soaked…. So yesterday, out came the driver seat then the carpet

I took off the external “A “post cover and removed the wipers then removed the windscreen lower Molding-Plenum Air Intake extension, that’s the big black cover held in place by the wiper blade spindles

View attachment 240644

View attachment 240645

I removed the “A” post outer cover by drill a small hole in the 3 plugs then screwed in a small screw and just pulled them out, saving the need to replace them
View attachment 240647

After a good inspection I found the wiper motor mounting plate was parting from the seal as it was clear the lower seal on the window was not working well and water was passing it, causing it to rust so I took it all out and also found that the wiper motor was loose on the plate and that explains why my wipers have always been to noisy
View attachment 240648

View attachment 240649

So I cleaned it all a coat of zinc, a liberal coating of sealer on both sided of the rubber seal and replaced it, all good so far, then …

View attachment 240650

The actual seal was split, and after a searching on the internet found out they are obsolete and now no one has any, so lots of a sealer later, it hope full stuck in place with a nice thin bead between it and the screen, I then did the top of the “A” post, and the bottom of the “A” post cover to try and keep it off the carpets, I have put the seat back but as it due to rain, so I’m leaving the carpet out to see if anymore water is getting in finger crossed

There is one more item related in my quest to find a replacement seal I came across a company that specializes in car seals, on their web page they had a few that at a push may have fitted an been a replacement for the ripped seal, I called them and they returned my call, and asked what the seal was for and that they would send me a sample to see if any of their current stock would be suitable

They requested a measurement of the seal so I sent them a CAD drawing of the seal in the hope they will find a good match of even remanufacture the seal….. I will post any feed back

westone · Jun 19, 2021

You can get the seal if you buy a new plenum panel from Land Rover or a trader,but it costs about £200. Atlantic British have a good video showing master mechanic Doug doing the replacement of the panel.
He does say in the vid that the windscreen seal is not designed to be waterproof and and drips should drain away,the rubber mouldings on the windscreen sides should take away most of any water through the drain holes by the wing.

Inside mine under the plenum I used some stick on Evostick flashband to seal up any seams to be sure .I put seal round the heater duct and a little peak made from a plastic milk carton on top of the duct to act as a peak to stop any water going in.
Your doing a grand job.

frostythor · Jun 19, 2021

So £200 to replace a bit that costs £21 no thank you, Im going to wait and see if the company I contacted comes up with an aftermarket replacement
my sealer worked fine on the glass, Im going to repair the hole, already got the repair section made up, it will be electric glued in place,( thats Welded ) it will be seam sealered, painted then every thing put back a fully sealed

Andy Warren · Jun 19, 2021

westone said:
You can get the seal if you buy a new plenum panel from Land Rover or a trader,but it costs about £200. Atlantic British have a good video showing master mechanic Doug doing the replacement of the panel.
He does say in the vid that the windscreen seal is not designed to be waterproof and and drips should drain away,the rubber mouldings on the windscreen sides should take away most of any water through the drain holes by the wing.

Inside mine under the plenum I used some stick on Evostick flashband to seal up any seams to be sure .I put seal round the heater duct and a little peak made from a plastic milk carton on top of the duct to act as a peak to stop any water going in.
Your doing a grand job.

I like the idea of the milk carton being used to help stop water getting inside the fan housing but so far I've only had water running down the outside of the housing.
I think the duct with the seal, according to the LR parts list, was only £65.60 inc vat p/no JKA100570 but it's now discontinued. Sorry I wasn't looking at the plenum seal just the heater intake.

Andy Warren · Jun 20, 2021

frostythor said:
Well I think I have found were the water is getting in, I thought it was here on the heated screen cable as the grommet was a very loose fit on the cable and not a tight fit in the hole, so I was cleaning out the seam ready to cover it in fresh seam sealer,....

View attachment 240800

But when I got to the lower right hand side below the wind screen I found this ...

View attachment 240801

so I think it needs a bit more than seam sealer ..

Blimey that's all you need. I think that's why on all vehicles you have to clean all the crap that accumulates in that area every few months, especially over autumn. Hope you get it sorted.

frostythor · Jun 20, 2021

HI all well having a good Father's Day, no more hole

Fully welded in

Gound down

Coat of Zinc primer

then a good coat of fresh seam sealer, follwed by a coat of Black Smoth Hammerites to finish off

I did get a bit carried away with the Hammerite

job nearly finished I have reinstalled the wiper motor , I also removed the black trim from the roof edge on the drivers side and redone the seam sealer from the back to the frontin the gutter

, just a bit of sealer on the cable grommet to do and hopefully that's it and I will have a dry carpet

lynall · Jun 20, 2021

Certainly a strange place to rot out, I could understand down in the bottom of the plenum/gutter area but at the top!

frostythor · Jun 21, 2021

well I am happy to report after raining most of the night I did not find a puddle of water in it this morning, and although I ended up with a large hole I think most of the water was getting in on the rubber grommet with the cables for the heated screen

westone · Jun 23, 2021

frostythor said:
well I am happy to report after raining most of the night I did not find a puddle of water in it this morning, and although I ended up with a large hole I think most of the water was getting in on the rubber grommet with the cables for the heated screen

You might find this handy if your seal supplier cannot do it.I bought a strip from these folk and it looks like it will do the job.Its not fitted yet as I had put it all back before it came , when it came.I tried it out on a bit of scrap from the old plenum panel which was in about 5 bits, just fell apart.

The reference is https://www.sealsdirect.co.uk/seals-products.asp?intDepartmentId=68
They do a moulding reference ETS3241

Old posting below with pics..cost about £20.00inc post.

Hi all,
the seal came today from Seals Direct, I mentioned earlier, this is for the scuttle panel to windscreen you cannot get the original unless you buy a new panel.It only comes with the panel now, not a separate item...bit of a cash creator for Land Rover.

It fits well ,the replacement seal has rubber barbs on it so is quite hard to get on and it has a metal shaping piece, it really grips when on, compared to the LR one which is 20 years old, although on the video the mechanic mentioned the LR ones fall off easy from new.

The seal is bigger, but I think it will do the job. see picture below. covers more of the panel and has the "banana" top part which is floppy to go up against the screen. next to it is an original to compare.
I have not fitted it to the car yet as when i replaced the panel i put sealer between the rubber and the windscreens will need to clean it out.
Having just done it, do not want to destroy it yet....I will be doing it.

The heater inlet is below this seal and can cause leaks on passenger floor i found with my old Disco, along with many other things ,but the design of this is odd its open, you can see where it is with the panel in place by looking for 2 of the lower bolts on the passenger side, picture below of it. Directly above this i sealed it up very tight....well hope so,!

ed736db6-0934-42d2-ac75-728627b1e946-jpeg.205710

b2e2d4c1-a662-4260-b0f0-361a1712c0f5-jpeg.205711

Feathers McGraw · Jun 23, 2021

frostythor said:
HI all well having a good Father's Day, no more hole

Apart from that, how's the Disco

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Attachments

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Active Member

Active Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Well-Known Member

Active Member

Well-Known Member

Similar threads