CK5
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Lower firewall water leak ideas?

Not sure why I waited so long to look into this. Mine was leaking behind the passenger kick panel. Was doing it while the truck was parked for some time so the carpet & jute had all been soaked. Passenger floor pan now needs replaced (so much for my rust-free desert truck) but since it had holes in it for drainage, I never prioritized fixing the leak. Plus it's been parked in my garage the last year so no rush. I just removed the cowl panel and around the hood hinge deflectors I had a bunch of leaves and dirt and gunk piled up. This wasn't letting the water drain between the outer & inner fender so it would pool and then drain through the hood hinge. The hood hinge drops into the cab and the water will go right into your kick panel if it makes it inside the hinge deflector. I gave everything a thorough cleaning and made sure there were no clogs between the outer & inner fender. Problem solved. When the interior goes back in, I've read here and elsewhere to seal the kick panel well. Hope that works!
 
Mine is still seeping after a hard rain and its coming down behind the glovebox somewhere. I might not have got the cowl seam all the way sealed there or maybe the heater box, and mine is the same as yours, some rust under the carpet and a hole where the sill panel screw goes in.
 
I replaced the windshield and there isn’t any rust in the frame and the gasket isn’t lesking but I still have this.

IMG_2363.jpeg
 
I’m ready for carpet but I have to fix this leak first. Its also running down the dash on the driver side above the brake.
 
Pull the windshield and seal. Inspect all seems, new seal with 3M window glaze.
 
The seal and window are good, no change with the new glass and we pulled the seal to check for rust and the frame is pristine, that was a happy moment. We are getting 3+ inches of rain Saturday so I’m going to chase the leak after the storm.
 
My only guess now would be the hood hinge wells.


That's if you used window glaze in the seal groves

We got a 1/4" today, I actually had to turn the wipers on and leave them on for 5 mins. Totally shocked they were good to go
 
I cleaned them out last winter so they should be good but I’m going to flood check everything again and see.
 
My leak was between the windshield glass and the gasket at the bottom corner. Water ran behind the dash and down the kick panel just like your picture. Over 5” is a lotta rain!
 
I think I have the leak fixed. It was the cowl. When I redid it a year ago, I couldn’t get all the way to the edges due to the air flap on the passenger side and the windshield wiper connector on the driver side. So I pulled both of those out and was able to reach down all the way around the edges. The I resealed the floor to firewall seem and found two grommets that were pulled out on the driver side. No leaks with the garden hose and it’s supposed to rain this week so if it’s good, I’ll be putting new carpet in soon.
 
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