T.Scott

Purchased an 07 Freestyle Apr 08. The head liner was stained and water damage to spare tire cover and carpet. Dealer agreed to locate and fix the water probem (vehicle is under warranty). To date they have attempted to locate and fix the problem 4 times. The vehicle is at the dealership as we speak. To date they have checked the moonroof seals, replaced the moonroof tray, replaced the headliner, spare tire cover and completed the Technical Service Bulliten which calls for the rerouting of the moonroof drain tubes (place a greater slope on them going aft, so the water can drain). The freestyle has 4 tubes, one at each corner of the moonroof to drain all water that makes it past the moonroof seal. The TSB indicates the 2 rear tubes may not allow the water to drain properly when the front end of the vehicle is slightly higher than the rear end of the vehicle. The front 2 drain tubes work fine. Last week I spent the entire day with the service manager (a qualified technician) at the dealer ship. We pulled all the inside panels that made contact with the headliner, ensured the the rear drain lines had a good slope aft and downword, disconnected the rear drain tubes at the moonroof and blew air through them to ensure they were clear and reconnected them. We then placed the car on level ground and added water to the left channel in the moonroof tray. The water drained out the left forward draintube. We then did the same to the right. The water drained out the right forward draintube. We then placed the front of the vehicle slightly higher then the rear and added water to the left and right channels. Since we removed the interior side panels we could pull (carefully)the headliner down to feel and see what was going on. While he poured the water into the right moon roof channel, I stuck my hand between the headliner and the roof (not easy to do but doable) directly below where the rubber drain tube connects to the moonroof tray. After only a couple of seconds I could feel and see water coming over the top of the plastic piece that the tube secures to. This plastic peice is siliconed to the moonroof tray and is supposed to collect the water that travels down the channel and direct the water to the tube. The TSB states that the drain tube should be capable of handling 1 liter per minute after the tubes are rerouted. We did the same to the other rear tube with the same result. If you continue to add water to the cannel the water runs along the headliner outward towards the middle seat window, then flows aft and down the pillar, behind the third row seat interior side panel, under the carpet, under the spare tire carrier cover and collects in the spare tire carrier cavity. We initially thought the plastic pieces that connect the drain tubes to the moonroof tray were not correctly installed so we reached in and pulled them off (held on with friction and silicone), cleaned them reapplied silicone and reinstalled them. Ran the water test....both sides failed. The nipple on the plastic piece that the tube connects to has an opening of approx 5/16 of an inch. I'm not a scientist or engineer, but it appears that the opening is to small to direct and allow water into the drain tube. Since the plastic piece is open at the top water simply spills over the top and onto the headliner. In short we spent all day confirming an extemely poor design. As far as I'm concerned this should not have been issued as a TSB. If told the dealership that this is their last opportunity to fix the probem as I feel that this is a major saftey concern. If you have an opportunity to see where the water flows, you'll know why this is a saftey issue. The water runs along the main wiring harness in the headliner that provides power to or receives signals from, rollover sensor, dvd, airbag etc etc. I will let you know how I make out once I get the vehicle back. I expect the delearship to have the vehicle for 2-3 days. I expect that a lot of freestyles are leaking but very few people actual look in the spare tire cavity or between the headliner and roof. I'm also wondering if the changed the installation on the 08 Taurus X.