Body - Water Leak From Roof Opening Panel (Moonroof)
TSB 07-3-602/19/07
WATER LEAK - ROOF OPENING PANEL
FORD:
2005 Five Hundred
2005-2007 Freestyle
MERCURY:
2005 Montego
This article supersedes TSB 06-15-7 to update the Service Procedure.
ISSUE
Some 2005-2007 Freestyle, 2005 Five Hundred and Montego vehicles may experience symptoms of a water leak from the roof opening panel (moon roof).
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Inspection Procedure Overview
^ On 2005 model year (MY) vehicles, inspect/install moon roof motor that has revised software to aid in proper glass closure and center glass. New software has a hard stop at the closed position to prevent accidental under/over closing of glass.
^ On Freestyle vehicles, reroute rear drain tubes. Current rear drain tube routing may not be adequate to handle water when vehicle is parked with the front of vehicle on a slight incline. Proper routing should allow 1 quart (1.0 liter) of water per minute for each rear drain.
For 2005 MY Vehicles
1. Inspect for original motor software strategy.
2. Open moon roof to vent.
3. Press and hold switch to close moon roof.
4. If moon roof closes and then starts to open after a brief delay, replace roof opening panel motor with a revised part.
5. Refer to Workshop Manual (WSM), Section 501-17 for removal and installation procedure. If motor stops when closed and does not start to open, motor already has revised software.
Center Moon Roof Glass
1. Use a piece of stiff paper (business card), or thin flexible plastic to check the seal tension on the left and right sides of the moon roof glass. Also, inspect the height of the moon roof per the WSM Section 501-17. If the seal tension is consistent side to side, and the height is within specification, do not adjust the glass.
2. If the glass height to the body roof panel is out of specification, follow the alignment procedure in the WSM, Section 501-17.
3. If the seal tension is uneven side to side, note the direction the glass needs to be adjusted and remove the glass per WSM, Section 501-17.
a. Carefully apply pressure to each of the metal attachment tabs in the OPPOSITE direction that the glass needs to be adjusted. Apply only enough pressure to achieve the necessary adjustment. Too much pressure may cause over adjustment or damage to the glass attachment points.
b. Reinstall the glass.
NOTE
THE ROOF PANEL SYSTEM MUST BE RE-INITIALIZED AFTER GLASS REMOVAL. WSM SECTION 501-17.
Freestyle Vehicles Only
1. Follow the WSM, Section 501-05 for removing the headliner, but STOP before removing the headliner from the vehicle.
NOTE
VEHICLES EQUIPPED WITH SIDE SAFETY CURTAINS MUST DEPOWER THE SAFETY RESTRAINTS SYSTEM (SRS).
Reroute Rear Drain Tubes
Vehicles Equipped With Side Air Curtains Only
1. Starting at the moon roof module assembly exit spout, remove and discard the first hanger clip.
2. At the first hanger clip location add new large C-clip. This clip will attach to the air curtain canister, 10.5" (267 mm) back from rear moon roof exit spout, so that drain tube is beside it. Cut off excess strap. (Figure 1)
3. Add new small tie strap C-clip to drain tube. This clip will attach to the air curtain fill tube, just below the A/C Duct (if equipped) and 20.7" (527 mm) back from rear moon roof exit spout. The drain tube should be pulled taught and attached close to the forward bend of the air curtain fill tube. Drain tube must position just below the air curtain fill tube at this position. (Figure 1)
WARNING
DO NOT CLIP OVER ELECTRICAL WIRE THAT RUNS PARALLEL TO AIR CURTAIN CANISTER AND AIR CURTAIN FILL TUBE.
4. Remove and discard the rear hanger clip located above the rear air curtain canister.
5. Move current tie-strap approximately 1" (25 mm) toward front of vehicle. This will pull the hose to a taught position, when clipped to the electrical wire-harness portable hole. (Figure 2)
6. Repeat procedure for the other side of the vehicle.
7. Check vehicle for water leaks.
8. Reinstall headliner.
Vehicle Not Equipped With Side Air Curtains
Left Side NON-AIRBAG
1. Pull back, but do not remove, rear quarter trim panel following procedure in WSM, Section 501-05.
2. Remove and discard first and second hanger clips from the drain tube.
3. Pull rear grommet out and disconnect remaining four (4) clips.
4. Move the two (2) existing foam blocks to new locations. (Figure 3)
5. Reroute and attach front of drain tube based on vehicle equipment. (Figure 3)
a. For vehicles equipped with rear A/C, using a standard tie strap(s) (may need to use two (2) depending on length of strap) attach drain tube to the top of the auxiliary A/C duct. Pull the drain tube taught before fully securing. Using another tie strap(s), attach drain tube to the base of the B-pillar A/C duct, near seat belt retractor. Be sure to pull the drain tube taught before fully securing.
b. For vehicle not equipped with rear A/C, tape drain tube to wiring harness in two locations, between existing retainers.
6. Route remaining drain tube to exit location and adjust drain tube grommet to fit drain tube exit hole.
7. Cut excess drain tube leaving 2" (50 mm) below grommet.
Right side NON-AIRBAG
1. Remove and discard first and second hanger clips from the drain tube.
2. Route drain tube behind electrical wiring located down the C-pillar. (Figure 4)
3. Tape drain tube wire harness below quarter window.
4. Adjust drain tube grommet to fit drain tube exit hole.
5. Route remaining drain tube to exit location and adjust drain tube grommet to fit drain tube exit hole.
6. Cut excess drain tube leaving 2" (50 mm) below grommet.
7. Check vehicle for water leak
8. Reinstall rear quarter trim panel.
9. Reinstall headliner.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
070306A 2005 Five 0.5 Hr.
Hundred/Montego: Test
Motor operation, Inspect
Glass Alignment, Replace
Motor (Do Not Use With
50282B, 15790A)
070306B 2005 Five 0.4 Hr.
Hundred/Montego: Test
Motor operation, Inspect
And Align Glass, Includes
Removal And Installation
Of Glass (Do Not Use
With 50282B, 15790A)
070306C 2005 Five 0.8 Hr.
Hundred/Montego: Test
Motor operation, Inspect
And Align Glass, Includes
Removal And Installation
Of Glass, And Replace
Motor (Do Not Use With
50282B, 15790A)
070306D 2005 Freestyle WITH OR 3.5 Hrs.
WITHOUT SIDE AIR
CURTAINS: Test Motor
operation, Inspect Glass
Alignment, Replace Motor,
Reroute Drain Hoses,
Includes Time To Remove
And Install Headliner (Do
Not Use With 50282B,
15790A)
070306E 2005-2007 Freestyle WITH 3.2 Hrs.
OR WITHOUT SIDE AIR
CURTAINS: Test Motor
operation, Inspect Glass
Alignment, Reroute Drain
Hoses, Includes Time To
Remove And Install The
Headliner (Do Not Use
With 50282B, 15790A)
070306F 2005-2007 Freestyle WITH 3.4 Hrs.
OR WITHOUT SIDE AIR
CURTAINS: Test Motor
operation, Inspect And
Align Glass, Reroute Drain
Hoses, Includes Time To
Remove And Install The
Headliner And Glass (Do
Not Use With 50282B,
15790A)
070306G 2005 Freestyle WITH OR 3.7 Hrs.
WITHOUT SIDE AIR
CURTAINS: Test Motor
operation, Inspect And
Align Glass, Replace
Motor, Reroute Drain
Hoses, Includes Time To
Remove And Install The
Headliner And Glass (Do
Not Use With 50282B,
15790A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
74502C52 02
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