Windshield Cowl leak, water in plug wells

[Michael Rose]

My 2003 EB recently developed a persistent ingnition mis-fire problem. The cause is water in the plug wells. Seems to be plenty of internet tracks on various Fords with this cowl leak, water in plug wells.
A few internet threads point to diverting water leaks from the windshield cowl.

However, I cannot find any good information on replacing the leaking cowl. There is some information about the cowl design regarding clip locations over the engine that leak water.

Appears there are 2 solutions. Replace the cowl so that the clips locations do not leak. Or improvise a drip-catch under the cowl to divert water off the engine.

I hope there is some knowledge on this forum to help with this problem.

 

[Trainmaster]

Are you sure it's not the windshield?

 

[Hamfisted]

What cylinders are reporting misfires?



As far as the cowl weatherstrip goes. Make sure it's intact and not torn or missing. If that weatherstrip is there and in good shape the water is coming from somewhere else.
If you need a new one there's still a few on Amazon: https://www.amazon.com/Ford-XC2Z-1502824-AA-SEAL-COWL-VENT/dp/B000NU7V90

 

[Michael Rose]

Are you sure it's not the windshield?

Yep, not the windshield. But, if it was, would not make any difference. The problem is water drips onto engine, gets into plug wells # 4, #8.

 

[Michael Rose]

The cylinders closest to the firewall, #4, #8.
The cowl, weather strip have no evidence of damage, or loseness. There are 2 clips under the hood, under the weather strip, just about perfectly in line with the plug line, are the culprits. They allow water to drip pass the weather strip.

What cylinders are reporting misfires?

 

[Michael Rose]

What year is the vehicle in picture? Does not look like my 2003.

[/QUOTE]

 

[Trainmaster]

I don't own that generation truck. If I did, and what you say is true, I'd be looking at silicone and perhaps some half cut hose, sponge weatherstrip and stuff like that. Hard to imagine Ford would.... Maybe not so hard.

 

[mdjeterva]

I had the same problem a couple of weeks ago, we had a torrential downpour, 6" of rain in a day. Next day I started getting a #7 misfire, finally decided to pull the coil and plug in case it was a bad coil or plug. Fortunately I had the compressor out and after I pulled the coil, I blew out the spark plug sleeve and saw clear water get blown out with a little grime. I checked the coil boot and both ends were rusty and a little dry rotted, so I go a new coil boot, applied the dielectric grease and fired it back up. The misfire was gone.

 

[Michael Rose]

..., so I go a new coil boot, applied the dielectric grease and fired it back up. The misfire was gone.

How are you going to prevent water from getting back in?
How many other plug wells have water in them?
What is the source of your water leak into the plug well(s)?

I have not pulled any C-O-Ps yet. Been taking to my local shade tree mechanic who is very reasonable. But I am not willing to keep paying for this every time it rains. Looking under the hood, not sure how to get to #4, #8 plugs. What has to be moved, removed to get to those plugs? Any special tools needed?

 

[Michael Rose]

I called local Ford dealer. They pretent not to know, just selectively ignore the internet info out there on this.

... Hard to imagine Ford would.... Maybe not so hard.