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Old 17-05-2008, 07:32 PM   #1
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Default Leaking Windscreen - How to Fix

There have been a few instances within these forums of what seams to be either a leaking windscreen, or a leaking firewall from a crack, that allows water into the cabin and onto the feet of the driver. This actually turns out to be a faulty spot weld under the wiper cowling. This how to shows you how to inspect and fix this issue.

Cost
For me it cost nothing as I already had the tools required at home, but it could be done for under $20 if you didn't have any silicon, or $40 if you had no tools, or couldn't borrow any

Tools required
Small flat headed screw driver
Medium Philip head screw driver (stumpy version is better)
Ratchet with 10mm socket, 13mm socket and extension bars
Silicon of any colour + Gun (or another type of sealant)

Step 1
Using the small screwdriver, remove the bolt covers on the wiper arms, and using your hands remove the weather seal that is in between the cowling and the engine bay



Step 2
Using the 13mm socket and ratchet undo both bolts holding the wiper arms to the motor. With draw the arms from vehicle.
Using the Phillips headed screw driver, undo the 5 scrivet's across the front of the cowling cover (2 in drivers side cover, 3 in the other)


Wiper arm Bolts


Scrivit location


Step 3
Maneuver cowling covers from the vehicle. This is very fiddle because of the tabs that are on each cover. Begin with the drivers side cover first. There are tabs that locate it to the windscreen (not Clips) and to each quarter panel. You may need to push down slightly on the cowling at the quarter panel to assist in removing it


Cowling removed

Step 4
Disconnect the wiper motor wiring and push out the grommet that the wiring enters the cowling through. Pull the harness and plug through the hole.
Using the 10mm socket and ratchet, undo the 5 bolts/nuts (3 bolts, 2 nuts) that hold the wiper motor assembly to the vehicle and withdraw from the vehicle (fiddly again)


Wiring harnes and gromet


Bolt location


Nut location

Step 5
Inspect the weld. If you think this is the cause, silicon it up, if not reverse the steps and put your car back together. Or you may want to silicon it just in case






Silicon in place. I didn't like the look of either weld so i did both


Step 6
Put you car back together in the reverse of the steps provided, taking care to line your windscreen wipers when you re-install them. This is a case of put them on in the approximate position, test them, and re-position if necessary. You should be able to see on your windscreen to approximate place where the wipers wipe.

Step 7
Clean up and enjoy a beer while marveling at your car modding abilities.



Cheers

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Old 17-05-2008, 09:12 PM   #2
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Fantastic write up mate! Thanks for taking the time to share this with everyone.
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Old 12-04-2009, 09:45 PM   #3
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Great write up superroo. You beat me to it I was about to do this myself as my car has this problem too. Will weld mine up when I when I weld up the front of the car.
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Old 18-04-2009, 08:04 PM   #4
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Your a LEGEND superroo.

Had this drama with mine, followed your step by step instuctions.

Problem solvered !!!
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Old 09-10-2009, 09:16 PM   #5
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Hey...



is this only happening to manuals or automatics as well ?


Thanks...


The Moose
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Old 10-10-2009, 02:13 PM   #6
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Not sure actually.
The cars that I Know have had this problem are all manuals, but since it seams to be the spot welds, i'd say both types of cars could have it.

Cheers
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Old 10-10-2009, 06:03 PM   #7
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Nice work Roo.

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Old 10-10-2009, 08:34 PM   #8
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And if you don't fix it, this is what can happen to the computer when the water runs down the loom and onto the computer.
Attached Images
File Type: jpg DSCF0019.JPG (60.2 KB, 353 views)
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Old 10-10-2009, 11:58 PM   #9
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Quote:
Originally Posted by DW260
And if you don't fix it, this is what can happen to the computer when the water runs down the loom and onto the computer.
Ooooohhhh nasty!

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Old 01-09-2010, 12:16 AM   #10
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Awesome! I had been (unsuccessfully) trying to solve the "leaking windscreen" problem on my AU1 XR8 (manual incidently) and came across this article.

Job was easy - not to mention cheap - and fixed the problem a ripper. Now I can drive in the rain without waiting for that inevitable drip, drip drip...

Thanks superroo
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Old 01-09-2010, 12:24 AM   #11
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shall be doing this VERY shortly.. ive had a few wet shoes since owner ship and that fried ECU looks MIGHTY nasty. do not want.
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Old 01-09-2010, 12:36 AM   #12
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Anyone got any idea what to do about doors (both front) the fill up when it rains? I know it's not a leaking windscreen, but is kind of connected.
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Old 01-09-2010, 12:08 PM   #13
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There are drain holes in the bottom of the doors.
Either they are blocked or have been covered up.

Solution - Pull off the door trims, and that foam sheet as well and inspect.

Cheers
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Old 01-09-2010, 03:20 PM   #14
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Quote:
Originally Posted by superroo
There are drain holes in the bottom of the doors.
Either they are blocked or have been covered up.

Solution - Pull off the door trims, and that foam sheet as well and inspect.

Cheers
Ta. Wasn't sure if it was something that leaked that shouldn't, or something that should leak but the water exit is blocked - I assumed the latter, and now you've confimred, I'll go digging with a pointy stick to unblock whatever is blocked.
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Old 01-09-2010, 03:30 PM   #15
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excellent write up. Rep points added
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Old 01-09-2010, 05:28 PM   #16
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Those spot welds support the brackets under the dash for the pedal box and they only seem to be more prevelant on manuals because of the strain put on them when using the clutch but I suppose they still could be a problen eventually for an auto.
I will be pulling out the dash on mine soon as i have had this problem for a long time now and have just put body tape over them. You know if this is your problem if you feet get wet when cornering or in very heavy downpours as the water goes over the raised part of the panel instead of going around it.

If anyone is interseted I could take pics and show how to fix this permanately as those spot welds will eventually break and you may lose some support for your pedal box. i will be doing this on my AU1 XR8 manual.
I've taken the dash out of my EB2 XR8 to repair the pedal box ,so I can't see the AU being that much different to do. Just a bugger of a job to remove the dash and half of the interior for about 20mins worth of welding (max).
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Old 01-09-2010, 05:29 PM   #17
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Great write up mate!!!!
rep a comin!!
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Old 01-09-2010, 09:04 PM   #18
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did mine last year from this write up and it fixed mine too. i couldn't beleive how much water came through a spot weld that you couldn't even see a hole in. thanks again superroo.
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Old 01-09-2010, 09:09 PM   #19
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Quote:
Originally Posted by AUIIPURSUIT
shall be doing this VERY shortly.. ive had a few wet shoes since owner ship and that fried ECU looks MIGHTY nasty. do not want.
Don't worry Chief, it's only about $700 fix if you can find a second-hand ECU... lol
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Old 05-09-2010, 05:46 PM   #20
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I now have dry feet thanks to you - you are a god :P
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Old 30-10-2010, 12:24 PM   #21
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This is why this forum is fantastic, was suffering from wet feet when ever I parked my Manual XR8 facing up hill, found the link and am now in the shed about to apply a bit of the right kind of Silicone to the two top spot welds that have a slight rust circle around them, hard to belive that these slight cracks would allow so much water to enter, congrats on a fantastic write up!!!!!!!!!!!!
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Old 31-10-2010, 11:32 PM   #22
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Many thanks.........
That drip has been driving me insane!
All fixed today

Thanks again
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Old 02-11-2010, 05:11 PM   #23
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I checked this the other day just to see if it was stuffed, luckily my car was owned by a complete tight **** and the welds still had original paint on them
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Old 14-03-2011, 10:51 PM   #24
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Will give this a go and hopefully will fix my water dripping problem.
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Old 18-11-2011, 12:24 AM   #25
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Default Re: Leaking Windscreen - How to Fix

yeah this tutorial worked a treat on my auto AU Futura Wagon, however I didn't have the water dripping on my feet like others on this thread have mentioned, but my carpet and underlay was soaked badly.... once i lifted up the carpet there was at least equivalent to an icecream container full of water i took out lol... but after following this... no more wet carpet. thanks for sharing!
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Old 18-11-2011, 12:44 PM   #26
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Thumbs up Re: Leaking Windscreen - How to Fix

Maaate, I reckon you nailed it..

I've had the same issue for some time now, always after rain I'd back out the drive way and/or go around the first left hand corner and get a wet right foot.

I did exactly as you suggested, found one of the spot welds was cracked and looking a little rusty so I cleaned it up and pushed silicon into it and all around.

Tested it by giving the car a good drenching with the hose and took her out the driveway and round a few bends, no leaks.

Great write up with helpful pix.

Thank you for sharing.

Cheers

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Old 01-12-2011, 03:23 PM   #27
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Default Re: Leaking Windscreen - How to Fix

yeah good thread my ute had a crack under the wiper motor had the windscreen replaced with no luck till I took it to a mate who owns a smash shop and he found it by elimination!
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Old 09-01-2012, 01:39 PM   #28
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Default Re: Leaking Windscreen - How to Fix

Good thread, as I replaced my windscreen yet I still get water leaking through the footwell where the clutch pedal is. Sure enough there was a broken spot weld.
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Old 15-01-2012, 08:54 AM   #29
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Default Re: Leaking Windscreen - How to Fix

I washed my AU for the first time since I bought it the other day and water leaked from the top of the windscreen in the middle right onto the shifter etc. It has caused the roof lining material to depart from the foam lining.
It appears the screen has been replaced at some stage and the fitment is very poor. Not a happy camper!
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Old 16-01-2012, 09:05 PM   #30
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Default Re: Leaking Windscreen - How to Fix

This fix is a good short term solution but eventually nearly all the spot welds break and you will have no support for the pedal box at the top and only from the bolts around the brake booster.
I have started diong some work on my AU1 XR8 which is manual and I had put some body tape over the spot welds a fair while ago but unfortunately more have cracked.Out of the 5/6 spot welds 3 have broken away and most probably the others are starting to crack.
If anyone is interested I can put up some pics of the problem and hopefully a solution so this will not happen again as it's very time consuming to fix. Just a bad design fault to spot weld this bracket to the body. At least the EB's have 4 bolts to hold the top of the pedal box in place which is a far better way. I know this as I had to repair the pedal box on my manual EB XR8 a while ago. Still had to remove the dash but at least the pedal box was bolted on at the top!!
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