AU BA BF Body structure

[nearlythere]

Hello,
I was wondering if anyone knows of images that show the body structure of the AU BA BF falcon bodys? As in the bare shell?
I have water leaks, I've researched alot and found some answers but I'm wanting a more in depth look into all so as to also rust proof areas.
My AU UTE is leaking water onto both foot wells and from the center of under the dash. This ute is a project so does not get driven, It is in the weather though.
The spot welds holding the steering column in place are not cracked.
All else under the wiper assembly also seems ok apart from a rust area ( also spot weld ) that holds some of the wiper bracket in place.
These AUs look to be a problem regarding rust and body seam seals.

[prktkljokr]

The plenum is usually the main culprit, with the actual windscreen a close second.

If you can see rust or a dodgy spot weld it has more than likely cracked through, with enough water running through the plenum it will leak quite a bit of water.

Have seen the smallest of leaks fill up a spare tyre well over the course of a day, so don't discount the rust of the wiper bracket being the culprit.

The only way to find the actual hole is to pull the dash, you will find there will defiantly be a small spot its coming through visible only from the inside, that's how I found mine on the RTV, mine was rusted under a spot weld on the wiper bracket.

[mad2]

you will also need to pull the rubber seal that goes up the 'A' pillar and check the body join's there as that's where i had leaks in my wagon (both sides). i also had an issue on the other wagon where the windscreen was not sealed correctly. the utes also have issues with water/rust along the back wall.

[XR Martin]

They leak through the top of the A-pillar also.
Pull the rubber seal up and you'll see where three sections join together , mine was leaking through there. Sealed it up with some black sikaflex body sealant.

Edit: beaten by mad2.

Stripped the interior out twice before working it out.

[Citroënbender]

You need a borescope or similar to see where the eyes can’t bend into.

Look into the scuttle corners, up under the offside bonnet hinge and towards the guard. Remove the wheelarch liner and look at the “stiffener” overbrace, it can trap compost and rust flakes from the scuttle and rust terribly - which then eats into the hinge pillar from outside.

[nearlythere]

Originally Posted by prktkljokr

The plenum is usually the main culprit, with the actual windscreen a close second.If you can see rust or a dodgy spot weld it has more than likely cracked through, with enough water running through the plenum it will leak quite a bit of water.Have seen the smallest of leaks fill up a spare tyre well over the course of a day, so don't discount the rust of the wiper bracket being the culprit.The only way to find the actual hole is to pull the dash, you will find there will defiantly be a small spot its coming through visible only from the inside, that's how I found mine on the RTV, mine was rusted under a spot weld on the wiper bracket.

Thanks mate, I will be treating that spot weld with rust converter and paint.

[nearlythere]

Originally Posted by mad2

you will also need to pull the rubber seal that goes up the 'A' pillar and check the body join's there as that's where i had leaks in my wagon (both sides). i also had an issue on the other wagon where the windscreen was not sealed correctly. the utes also have issues with water/rust along the back wall.

the A pillars are sorted mate as is the rear. Those outside speakers ( vents ) are an issue with leaking but I've also sorted those.
I need all water leaks fixed before the whole interior including carpet is put back in. I don't want leaks, condensation and then mold! lol

[nearlythere]

Originally Posted by XR Martin

They leak through the top of the A-pillar also.Pull the rubber seal up and you'll see where three sections join together , mine was leaking through there. Sealed it up with some black sikaflex body sealant.Edit: beaten by mad2. Stripped the interior out twice before working it out.

onto it mate! I'll be taking off the guards also to inspect every seal I find

[nearlythere]

Thanks mate

[nearlythere]

Man that plenium holds alot of water, no drain holes or anything..

[XR Martin]

Don't forget the bonnet cable grommet.
Mine was dislodged which is where I first thought the water was coming in.

[mad2]

Originally Posted by XR Martin

Don't forget the bonnet cable grommet.
Mine was dislodged which is where I first thought the water was coming in.

which was where i 1st thought mine was leaking.

[nearlythere]

Originally Posted by XR Martin

Don't forget the bonnet cable grommet.Mine was dislodged which is where I first thought the water was coming in.

sorted that mate

[nearlythere]

So its raining here, And the back passenger floor has a puddle :( I know its not the vents but it is coming from the the top area. I did have the rear glass replaced around 18 months ago...Man these AUs! LOL

[XR Martin]

Rear firewall rusts at the lip under the window.
Pull the carpeted walling off and you'll probably see the rust/water stains.

[nearlythere]

Originally Posted by XR Martin

Rear firewall rusts at the lip under the window. Pull the carpeted walling off and you'll probably see the rust/water stains.

All is already out mate.
I ran new sealant across the seams outside and all is fixed.
Now for the front but I need dry weather to tackle that one.
The water that pools up in the wiper motor area is ridiculous.

[oldel]

You have blocked drains then. That is a problem - causing overflow or has contributed to rusting out.
The front cowl area has drains, nothing plumbed though - it drains out under the front guards.
Blast it with a hose in the far corners until you see water come out under the guard/a pillar base. Or feel around poking with a large cable tie end or something similar.

All mine leak water, never been able to get to the bottom of it no matter how many repairs tried, winter sucks. I cut away the underlay foam on the leaking side, and just pull it out for winter. The carpet is pretty water resistant, when the foam gets wet it's not fun.

[nearlythere]

Originally Posted by oldel

You have blocked drains then. That is a problem - causing overflow or has contributed to rusting out.The front cowl area has drains, nothing plumbed though - it drains out under the front guards.Blast it with a hose in the far corners until you see water come out under the guard/a pillar base. Or feel around poking with a large cable tie end or something similar.All mine leak water, never been able to get to the bottom of it no matter how many repairs tried, winter sucks. I cut away the underlay foam on the leaking side, and just pull it out for winter. The carpet is pretty water resistant, when the foam gets wet it's not fun.

I need to take a photo to show you.
It drains from the sides but the center is a pool about 2cms deep. There are no drain holes in the center :/

[nearlythere]

[nearlythere]

[mad2]

'should' drain away .... maybe check the ends for any blockages?.

[nearlythere]

Originally Posted by mad2

'should' drain away .... maybe check the ends for any blockages?.

That's the thing, both ends are dry on each side of the puddle as when it gets to a certain level no more water can leave the puddle