wet headliner 04 Tundra Double Cab

It's raining outside, and for the first time since I bought my '04 double cab the headliner is dripping rainwater from the dome light console. No recent trauma or fixes or mods. I sealed up the 3rd brake light, still leaking. Anyone else experiencing sudden leaking at the top? Could it be leaking from anywhere except the windshield seal?

 

Man. That sucks. Let's get a lot more info. Pics? Is anywhere else wet at all? Are the drip rails all good under the rubber? It's been awhile but I thought my 04' had rubber drip rail covers running from windshield to rear. They may be rusted under those.

 

https://www.ebay.com/i/282476433352...MIr8yZ0Mai5gIVgspkCh2Hng8PEAQYAyABEgJnwvD_BwE

I think mine were like this. I believe this is an access cab, but you get the idea.

 

do you happen to have a sunroof?

 

Thanks NoRcptn. No sunroof. I suspect drip rail intrusion but not sure how to remove to inspect.

 

I just skimmed it but I think there are a few PDF's here on how to do it.
https://www.tundras.com/threads/replacing-roof-molding.44345/

 

Yes. I’m currently fixing a leak from the same thing.

 

Mine was coming through from an improper replacement on the windshield as well as water puddling where the cab rain gutters hit the windshield weather stripping and water was sitting And getting through the pinch weld where the window sits. I couldn’t see everything unfortunately until removing my windshield. I’ve been repairing for a few days.

 

I suspect leakage under the passenger side roof channel mldg. I'll remove and inspect. Any advice?

 

Yeah if it is try and pull back the weather strip to see if you have rust along the window seal or actual urethane used to seal the window. Sometimes you can see it from the top. It’ll rip off some glue and leave some material on the roof channel when you remove it. Be careful getting that off then either reapply the 3M adhesive it uses or maybe the same better sealant so water doesn’t puddle where it meets the windshield.

 

Here's what I did: I peeled up the roof gutter trim strip from the front (first few inches are stuck down pretty good), cleaned the area (lots of dirt under there), used compressed air to blow out as much moisture as possible, identified a pocket where water intrusion seems likely (at the front end of the roof trim strip), filled it with hot glue (yes, hot glue don't judge me), then cut off the nib on the front end of the trim strip (it fits into the pocket I filled with hot glue), and finally stuck down the trim strip with exterior grade 3M double stick tape (the clear stuff they sell at Home Depot). Let's see if it's the fix.
I did all of this on the passenger side because that's where I traced back some water dripping down the A pillar into the carpet. Attached are some photos.
Stay tuned, we expect more rain in a few hours.

 

Don’t mean to burst your bubble but hot glue will brittle and break quite easily. Hopefully that will help you identify the leak though. A clear silicone or window Mastic may be a better long term fix. Fingers crossed!

 

I need to do this to mine. After 18 years the weather stripping on my roof looks bad. Those things are expensive to replace though.

 

I just got the brilliant idea of running the hose on the area instead of waiting for rain. Keep in mind I dried out the areas that were wet before I attempted the fix. So the result after hosing it down and running my finger between the headliner and windshield is this: fresh leakage at top and center of the windshield. Apparently the top of the windshield seal is leaking, right down into the headliner. I suspect my "fix" was unnecessary. Next step - replace windshield seal (and probably the windshield too). Any other ideas?

 

yeah that’s not where it was coming from. Its a pain to scrape the adhesive off unfortunately. It’s underneath the weather stripping from the windshield is my guess. I hope the glue works or maybe some auto urethane for window will work to stop it. Good luck. I have some pics. This just happened to me.

All along the front of the windshield the water was leaking as well but that was because I found a little hole in the top corners where the roof stripping hits the window weather stripping and puddles and gets in between the top of the roof and the cab and leaks down through the pinch weld. So it looks like it’s coming from the middle which will probably be pretty rusted by now but there’s probably an opening starting at the corners from my experience . Let us know what happens when you remove the windshield. Oh and don’t take it to safelite or anyplace like that when they take your window off and there’s an opening or a little too much rust. They can’t install a new window or put your old window back in. They’ll make you tow it to a body shop to have expensive metal work done to completely eradicate the rust.

 

Oh and it could be from the middle of the windshield due to surface rust separating the window urethane just enough to allow drops through. Found out water can get through the smallest pinhole.

 

I appreciate the insights and advice. It looks like you're in the middle of doing yours - good luck, hope it goes well.

 

I applied the 2-3 day temporary fix (duct tape across the top seam) and had zero leakage in overnight rain. Faulty window seal is the confirmed cause. Thank you for your advice and insights Volt92 and NoRcprtn

 

For anyone interested in this problem, what follows is the procedure I performed. it seems 1st gen Tundras are known for rust in this area. Mine was also a victim of such. Confirmed when I dug out the seal. Leaving the window in place I removed all non-metal components from the area between glass and metal body, then wire brushed away all residue and sure enough found rust. I applied a coat of rust converter, then sprayed a coat of black Flex Seal on top of that (thanks Phil), then topped it all off with a hefty but level bead of black Dap Dynaflex 230 elastomeric sealant. It has proven to be a salutary fix. It even looks like it belongs there. The nice thing about the Dynaflex 230 is a) you can get it at your local Home Cheapo, b) its inexpensive, c) it never hardens up but remains flexible, and d) unlike silicone it won't be terribly hard to dig out if I ever have to do it again.

 

Epilogue - after a number of years and big rain storms I've seen no more leakage.