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  1. #1
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Windshield bottom seal leak

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    The seal at the bottom of the windshield is letting water through, runs into cabin air filter and floods passenger side.*
    How to re seal it?*

    The seal is created by a groove in the windshield holder where the lip of the plastic cover goes on.*

    Not sure how it originally seals, but I assume I have to fill the groove with sealant then press the lip of the cover in.*
    What sealant should I use? Black RTV? Pure silicone? Other Bathroom sealant?

    https://cimg4.ibsrv.net/gimg/www.aud...cfab1f92ff.jpg
    https://cimg5.ibsrv.net/gimg/www.aud...acbf6b6a0b.jpg
    https://cimg6.ibsrv.net/gimg/www.aud...9c90fbcbfc.jpg
    https://cimg7.ibsrv.net/gimg/www.aud...c6a6635e3b.jpg
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  2. #2
    Established Member Two Rings AudiNike12's Avatar
    Join Date
    Oct 10 2017
    AZ Member #
    408194
    Location
    Sweden

    I've not sealed mine and it doesn't leak any water
    Audi A6 Allroad 2.7T -04
    Audi A6 2.4 Sedan -04

  3. #3
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    If it pops away from the glass, water runs through and floods interior.
    Question is: how to prevent from lifting up.
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  4. #4
    Veteran Member Three Rings m_haiser's Avatar
    Join Date
    Apr 24 2011
    AZ Member #
    74529
    My Garage
    Highland Green Allroad
    Location
    Oregon Coast

    you should check that the seal around your cabin filter housing is intact. as it is raised from the rain tray slightly water should not get into it. nor will that plastic cover being raised or even missing cause water ingress

  5. #5
    Established Member Two Rings
    Join Date
    Dec 13 2017
    AZ Member #
    411113
    My Garage
    '02 S6 Avant, '17 Mk7 Golf Wolfsburg
    Location
    Santa Ana, CA

    My rain tray deflector cracked on the passenger side corner right above the cabin filter, had the same issue and ruined my brand new filter. Ordered a new rain tray from local Audi dealer, just have to go pick it up. It was 10 bucks more the ECS, but you don't have to deal with ECS.



    It clamps down against the windshield in 3 places so make sure yours is intact and still clamped down.


    Part # 4B7 819 403 A 01C


    https://www.ecstuning.com/b-genuine-...4b7819403a01c/

  6. #6
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by m_haiser View Post
    you should check that the seal around your cabin filter housing is intact. as it is raised from the rain tray slightly water should not get into it. nor will that plastic cover being raised or even missing cause water ingress
    The water runs UNDER the plastic windshield cover; cover raised up 1/4 inch.
    Temporarily pressed down and taped with ductape to teh windshield glass, water runs onto it and either drains to side, or runs over it and the larger cover (over battery, cabin air filter, etc) drains it away. nothing goes into the cabin.

    Therefore I only have to make sure that the "lip" (on lower windshield cover) stays sealed in the "groove" (windshield bottom, part of chassis/windshield).
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  7. #7
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by Gogeees View Post
    My rain tray deflector cracked on the passenger side corner right above the cabin filter, had the same issue and ruined my brand new filter. Ordered a new rain tray from local Audi dealer, just have to go pick it up. It was 10 bucks more the ECS, but you don't have to deal with ECS.
    It clamps down against the windshield in 3 places so make sure yours is intact and still clamped down.

    Part # 4B7 819 403 A 01C
    I have to check (now that it is glued in with pure silicone sealant) that the 3 clamps are on. Likely missing. Anyone have a picture how they look like (to search in my fastener bucket or order)?
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  8. #8
    Established Member Two Rings
    Join Date
    Dec 13 2017
    AZ Member #
    411113
    My Garage
    '02 S6 Avant, '17 Mk7 Golf Wolfsburg
    Location
    Santa Ana, CA

    I think they are something like this - 8D0 819 145 A

    https://www.ecstuning.com/b-genuine-...ch/8d0819145a/

  9. #9
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by Gogeees View Post
    I think they are something like this - 8D0 819 145 A

    https://www.ecstuning.com/b-genuine-...ch/8d0819145a/
    Thanks. Sure look like it:

    https://c1552172.ssl.cf0.rackcdn.com/74127_x800.webp
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  10. #10
    Active Member One Ring
    Join Date
    Dec 24 2012
    AZ Member #
    106329
    Location
    Maine

    Quote Originally Posted by vtraudt View Post
    The water runs UNDER the plastic windshield cover; cover raised up 1/4 inch.
    Temporarily pressed down and taped with ductape to teh windshield glass, water runs onto it and either drains to side, or runs over it and the larger cover (over battery, cabin air filter, etc) drains it away. nothing goes into the cabin.

    Therefore I only have to make sure that the "lip" (on lower windshield cover) stays sealed in the "groove" (windshield bottom, part of chassis/windshield).
    I have the same problem. Plastic tray will not stay engaged with the groove at the bottom of the windshield. Water runs under it and into the cabin filter. My fasteners are in place. It appears that the tray may be warped. I am going to try using silicone sealant to keep the tray in the groove.

  11. #11
    Veteran Member Four Rings hoganalley's Avatar
    Join Date
    Feb 23 2007
    AZ Member #
    15868
    Location
    Burlington

    I have a similar problem, although it doesn't leak frequently, but I had a crack in the windshield and when it was replaced they didn't set it at the correct dims..... So my cowl cover doesn't sit properly but at this moment in time I have zero water ingress

    Sent from my ONEPLUS A6003 using Audizine mobile app
    05 allroad 2.7T Stock

    99.5 A4 1.8T K04 - Sold

  12. #12
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    First time around I just used a few dabs of black RTV, did not hold long and cover popped up again, leaking inside.
    This time I cleaned the entire groove and filled the entire groove, and used silicone.
    We'll see how long it holds.
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  13. #13
    Established Member Two Rings danspach's Avatar
    Join Date
    May 03 2011
    AZ Member #
    74939
    My Garage
    2001 911 turbo, 2007 VW Touareg, 2003 S6
    Location
    Hartsdale, NY

    Have a similar issue with water in the cabin. Luckily my driveway is sloped so my trans control unit was spared.

    My issue is not with the seal against the windshield, though. The cabin filter housing itself was not only suffering from a long-degraded seal around the edge but is also has a huge crack allowing an easy way for water to find its way in. This is the part you drop the filter into and it has three nuts that thread onto studs holding it on.

    There is one on the inboard side of the filter housing (under the filter when the filter is in place...this is where mine cracked) and two on the outboard side using two tabs.

    I canít figure out how to get the last nut off. Itís under the windshield and tucked behind the hood hinge.

    Anyone have any clues?

    Thanks!
    Last edited by danspach; 10-09-2018 at 06:30 AM.
    - Dave
    ____________
    '01 911 turbo
    '03 S6
    '07 Touareg

  14. #14
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  15. #15
    Veteran Member Three Rings
    Join Date
    Jun 07 2005
    AZ Member #
    6784
    Location
    Shepherdstown, WV

    Quote Originally Posted by vtraudt View Post
    First time around I just used a few dabs of black RTV, did not hold long and cover popped up again, leaking inside.
    This time I cleaned the entire groove and filled the entire groove, and used silicone.
    We'll see how long it holds.
    The issue with silicon is that while it may hold now, once you need to remove the tray for any reason the silicon will tear and you'll have globs all over the place making proper reinstallation of the tray impossible and probably create more leaks.


    It is a short term fix that may create long term issues.

  16. #16
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by chris86vw View Post
    The issue with silicon is that while it may hold now, once you need to remove the tray for any reason the silicon will tear and you'll have globs all over the place making proper reinstallation of the tray impossible and probably create more leaks.
    It is a short term fix that may create long term issues.
    Just need to clean the groove again (just like I did this time) IF/WHEN I need to remove (only reason would be if wiper arms need to come off for whatever reason).
    Very acceptable if it works (compared to the alternative of flooding car rendering it non moveable, or shelling out $100+ for a new tray if the old one does not 'hold' anymore).
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com



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