95 D1 passenger side "mystery" water leak

[JTJ123]

I am going crazy trying to find the leak on the passenger side floor of my 95 D1. Over the past 6 months I have searched all threads on leaks and have tried just about everything everyone here has recommended.

At this point I have taken out the carpet, kick panel and glove box. I have resealed around the windshield and every tube or wire going through the fire wall. After a long rain, water can be seen running down the wall where the passenger side kick panel was removed. If I follow the water stream up it is coming from a horizontal seam in the metal about the same height of the air bag. By taking the front quarter panel off will I be able to see into the "cavity" just infront of where the air bag is mounted? If I take the D1 to the car wash or soak it with a hose I cannot get it to leak. It takes a good day of steady rain to get the leak going. Is it possible that the sun roof drain tube is disconnected? I have tried pouring water down the sunroof drain and it comes out the drain near the mud flap in a steady stream.

I am missing something. Any suggestions would be greatly appreciated!

Thanks
JTJ

 

[roverX]

How is your heater core?

 

[JTJ123]

I believe the heater core is OK because it will leak parked in the driveway.

 

[clayatem]

It's a body seam leak.
It has to fill a well up them overflow.
Try this take the water hose and let it run just over the bottom right corner
of the window (about 30-60 mins).
That way you see if it's coming from the top or the bottom of windshield
You also take the cawl at the bottom windshield off and see if that drain is
stoped up. There are alot of body seams in that well.

 

[barefoot]

i have a leak in passenger floor as well....i have not yet got around to checking it out but if it is the heater core, would the heater still work flawlessly? as for sunroof gutters...will check tomorrow. oh yea 96 d1 135k!

 

[JTJ123]

Clay,

Thanks. I will try it as soon as I fix the ****** oil cooler leak that just came about.

 

[sven]

It's a body seam leak.

Yup thats what my RRC had on both sides. Mine was on the lower corners underneath the windsheild. I think these leaks are more common than the traditional windsheild leak. Its best to fix these leaks ASAP since these trucks rot out quicker than you think.

 

[Chris-St Louis]

94 and 95 Discos had water come in from the HVAC Intake. The fix was a cover that protected it. I'm at home, So I cant look it up, but I will later.

It would drip down the firewall on the inside, and corrode wiring and such.

 

[only1earth]

I had the same problem a couple of years ago with my D1 and it ended up being a clogged air conditioner condensate line that usually drains out underneath the Disco. When the drain line gets clogged from mud, road sludge, etc. then the moisture builds up in the system until it eventually leaks into the front passenger foot area. I can't describe where the condensate drain line comes out under the vehicle (sorry, maybe someone else can help with that), but the fix was to remove the clog with a narrow shafted phillips screw driver. End of leak. I don't know if you are using your AC where you live, but it's worth looking into, and best of all, the fix is super easy and free! Good luck.