Leaking at A-Pillar - not sunroof - not windshield - ideas?

All. I'm in a pickle. My 2016 Expy XLT has started to leak and I notice the headliner at the top of the driver A-Pillar is super wet. It then appears to drip down just over the emerg. brake and lands on my driver-side floor mat. This just started a week or so ago.

I could sure use the help coming up with ideas on how to chase down the leak. A couple of things that may help when considering options:
1. There is no sunroof in the truck.
2. I took it to my auto-glass place and they water tested the windshield seal and said that there is no leaking around that seal.
3. The seal around the driver's door looks to be in perfect condition. No tears or crimps.
4. I re-sealed the roof rack bolt holes on all four corners, but that did not stop the headliner from getting wet.
5. about 4 years ago the truck had roof damage near the back hatch (tree fell on it). It was repaired before I bought it, and I have had no problems since then.

If you're an expert on this...or have seen this before, I would very much appreciate your help. I really don't want to leave the truck with a body shop until I have tried all of the tricks you all may suggest! Hope to hear from you. And thank you.

Did you actually lift the roof rack rail and inspect underneath it ? Not uncommon to have a rust hole underneath the roof rack(s) . That would allow water into the roof substructure.

@Hamfisted yes. Did inspection and didn’t see any holes there. In fact the bolt holes all looked pretty good and without rust themselves. Any other ideas?

Drop the headliner and look for water trail .

fidget247 said:

All. I'm in a pickle. My 2016 Expy XLT has started to leak and I notice the headliner at the top of the driver A-Pillar is super wet. It then appears to drip down just over the emerg. brake and lands on my driver-side floor mat. This just started a week or so ago.

I could sure use the help coming up with ideas on how to chase down the leak. A couple of things that may help when considering options:
1. There is no sunroof in the truck.
2. I took it to my auto-glass place and they water tested the windshield seal and said that there is no leaking around that seal.
3. The seal around the driver's door looks to be in perfect condition. No tears or crimps.
4. I re-sealed the roof rack bolt holes on all four corners, but that did not stop the headliner from getting wet.
5. about 4 years ago the truck had roof damage near the back hatch (tree fell on it). It was repaired before I bought it, and I have had no problems since then.

If you're an expert on this...or have seen this before, I would very much appreciate your help. I really don't want to leave the truck with a body shop until I have tried all of the tricks you all may suggest! Hope to hear from you. And thank you.

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The water channels that run the length of the roof on the far outer edges are sealed with a really ****** squishy foam like sealant, id bet there’s a gap somewhere in that seal and water is getting under it and traveling downward to the A pillar and in through there. This area pictured below

@black_limited I have been looking at those and don't see any leaking but there may be a crack I can't see. Do you have any experience making a repair with that ****squishy foam like sealant?

fidget247 said:

@black_limited I have been looking at those and don't see any leaking but there may be a crack I can't see. Do you have any experience making a repair with that ****squishy foam like sealant?

Click to expand...

Lol I do not but from what I’ve heard it’s a pain and sorta messy

An easy fix would be to run a even matched strip of black eternabond tape down the track. It will seal any water leakage and look good as well.

You could always run a small bead of clear silicon down the seam.