Ford Galaxy / Ford S-MAX. Manual - part 1021

Door seals

If water appears at the bottom of the door, it is possible that the door seal behind the door
trim is damaged. If the door is intact, water can enter through the window weatherstrip and
flow out through gaps on the underside of the door. If the door seal adhesion is faulty or
the door seal is damaged, water can get into the interior.

Fastening bolts could be loose or clips incorrectly positioned on door modules.

Corrective action

Depending on the door seals used, different sealing methods can be used.

NOTE: The drainage holes on the underside of the door may not be blocked - if they are,
clean them. Defective films and foam seals must be replaced.

Once the adhesive surfaces have been cleaned, plastic films must be stuck with double-
sided adhesive tape or replaced.

Leaky foam seals are sealed with Butyl tape or replaced.

Plastic door modules are fitted with a weatherstrip, which cannot be replaced. Seal the
leaky point with Butyl tape or replace the part.

Door weatherstrip

Leaks can be caused by badly fitted seals. In particular, areas with radii -Arrow- must be
thoroughly checked.

Door seals can develop leaks due to:

Damaged or expanded seals.
Ageing.

Description

Seal/adhesion

Clips

Door speaker

Insufficient contact pressure.
Inadequate contact area for seal on body part.
Uneven welded flange thickness because of several layers of body panels or production
tolerances.
Kinks.

The contact pressure of a seal can be determined using a strip of paper. If a strip of paper
trapped in the closed door can be pulled out easily, the contact pressure is too low.

To resolve

Replace damaged or aged seals. Prevent kinks.
The contact pressure can be changed by adjusting the catch bolt or correcting the panel
flange.
Even out the uneven welded flange thicknesses. Properly repair any paint damage that
occurs. If the bodywork flanges are very uneven, appropriate alignment work must be
performed. Pay particular attention here to the new corrosion protection which needs to
be applied afterwards.
If water entry is caused by a spot weld (burr on the surface), this must be rectified and
appropriate corrosion protection applied.

Tailgate sealing rubber

Leaks at the tailgate rubber seal have the same causes and remedial measures as for door
rubber seals. Especially vulnerable areas -arrows- must be thoroughly checked.

Rubber grommets / plugs

Rubber grommets or plugs are fitted at numerous points on the body. They are frequently
used as seals for cables, hoses or actuating links. Rubber plugs are frequently used for gaps
caused during production.

Example: Possible problem locations in the tailgate area

Leaks can be caused by badly fitted or damaged rubber grommets and plugs.

Description

Hinge seal

Cable duct

Damaged cable insulation can also cause leaks.

Where components are bolted on, water can enter if there are inadequate seals at the
connection point.

To resolve

Correctly fit rubber grommets / plugs. During fitting, ensure that the sealing lips are not
trapped and are applied properly.
The contact area of the rubber grommets / plugs can also be sealed with PU sealing
compound.
Replace the damaged rubber grommets and repair the damaged cable insulation.
Smooth the panel deformations in the contact area of the plugs.

Heater housing/ventilation

Loose butyl sealing strips, damaged sealing surfaces or a trapped carpet can cause leaks
around the heater housing / ventilation Arrow. Badly positioned or badly fitted hoses can
also be responsible for water entry. Water drains must not be blocked

NOTE: A large quantity of water flows through the water tank. If there are leaks in this
area, it is essential to ensure that the water drainage mechanisms function correctly.
Drainage openings may not be blocked or stuck. Leaves and other dirt must be removed
before troubleshooting.

Corrective action

Before the actual repair, make sure that the water drains are not blocked or stuck.

Remove the heater housing / ventilation and fit a new Butyl sealing strip. Damaged sealing
surfaces must first be adjusted. A trapped carpet must be removed.

Seal welds

PU sealing beads are applied to welded or riveted connections Arrows to seal the interior
of the vehicle. Incorrectly applied or damaged seal welds can allow moisture to penetrate
into the interior of the vehicle. It is also possible that sealing beads whose shape and size
appear to be intact actually have poor adhesion.

Corrective action

Incomplete seal welds must be supplemented with PU sealing compound. Damaged seal
welds must be removed and re-applied properly. Make sure that any residual moisture is
effectively removed before a new seal is applied.

Attached parts

The add-on parts include:

Exterior mirros, handles, controls.
Mouldings, roof mouldings, lettering.
Roof aerial, roof rack or connections for roof rack systems.
Bumper mountings.
Injection nozzles, door contact switches, bump stop rubber.
Control unit seals.
Tail lamps.
All kind of screwed connections (pedal block, door and tailgate hinges)

Example: Possible water entry points at the rear lamp

Add-on body parts must be fitted with seals, grommets or sealing compound to prevent
water entry. However, even when a sealing system is fitted, the screw thread may still
cause leaks.

Corrective action

Seals must be tested and, if necessary, replaced. Check contact surface and adjust if
necessary. Points sealed with sealing compound must be thoroughly cleaned and the seal
replaced. Check grommets and replace if necessary. At all screwed connections, seal the
thread with an appropriate sealing material.

Description

Clips

Gaskets.

Rubber grommet

Content .. 1019 1020 1021 1022 ..