B. Leakage at Joint / Windshield Frame Seal & Front Side Seal
Models Affected: 1995 900 ConvertibleVIN Serial No. Range: see steps below
Symptom:
Water drips on the inside of the window when the car is being washed or during heavy rain.
1. Increasing the size of the drain hole in the upper corner of the windshield frame seal
Cars Affected:
S7000001 - S7015800
Action:
a. Push the smooth end of a 5/16" (8mm) drill bit into the drain hole. Withdraw the drill bit slightly so that the rubber edge comes out with it. See Figure 3 on next page.
b. Using a razor blade, cut out an 5/16" (8mm) hole as shown in Figure 3, using the drill bit to support the edge you are cutting. Make sure that the cut edge is even and that the diameter of the hole is 5/16" (8mm).
2. Increasing the size of the drain hole at the lower end of the A-pillar
Cars Affected:
S7000001-S7015800
Action:
Enlarge the drain hole upward toward the windshield frame so that it measures 3/8" high x 9/32" wide (10 x 7mm). See Figure 3.
3. Extending the drain channel on the windshield frame seal
Cars Affected:
S7000001-S7018602
Action:
Extend the length of the drain channel to 25mm from the mold seam as shown in Figure 4.
4. Adjust the front side seal outward at the front edge
Cars Affected:
As necessary
Action:
a. Undo the front screw and push the seal out. See Figure 5.
b. Adjust so that the front seal protrudes about 2mm beyond the windshield frame's upper seal when the top is resting on the windshield frame. When the top is latched to the windshield frame, a slight swelling of about 2-3 mm should be observable in the front side seal.
5. Gluing the windshield frame seal at the corners
Cars Affected:
S7000001-S7024121
Parts:
Butyl tape source locally
Glue, Sikaflex 255 (310 ml tube) 30 07 127*
*Enough for about 10 cars
Action:
To prevent water leakage, the windshield frame seal should be glued as described below:
a. Remove the windshield frame seal and remove any butyl tape.
b. Clean the surface where the glue and tape are to be applied.
c. Affix butyl tape in the depression in the front of the seal holder, about 14-16" (350-400mm) long, extending from the corners. See Figure 6.
d. Affix butyl tape to the windshield frame from the corners down along the A-pillar. See Figure 6.
e. Then apply a few beads of Sikaflex glue, as shown in Figure 6.
f. Fit the seal, making sure it is about 1/2" (13mm) over the plastic cover on each side. See Figure 6.