Hard top water leak

Blfranks

Looking for some advice or suggestions. I ordered a 2025 heritage edition in April of 2025, took delivery in July. I absolutely love my bronco. But... I've been dealing with a leak from the beginning which is yet to be resolved. The leak is over the passenger side sun visor and runs in in-between 2 trim panel, also a few times water has run down the a pillar where the airbag is on passenger side. After I noticed the leak the first time, I immediately called the dealer, they found a TSB for a new/revised header seal. So they replaced the seal, the next time it rained, it was still leaking, exact same place. Called dealer and took it back in again, they removed header seal, and re-sealed it again. Next time it rained, same thing, still leaking from same place... now I'm furious. Took It back into the dealer again, this time they kept it for a few days, went over all the body seams around the header and re-sealed them, put the seal back in and even used sealant around the bolts that hold the header seal in place. They kept it inside for 2 days in the heat to make sure the sealant cured. Then they did a leak test by spraying water on top several times and leaving water sit on it over night. They checked for leaks and nothing, so it looked good. 3 weeks later we get rain after a very long cold spell, and it's still leaking in the exact same place. Some odd facts... it doesn't leak driving in the pouring down rain. It only leaks after it sits in the rain for a few hours, and even then it doesn't run in until you start to drive and take a couple turns, then the water goes to the passenger side and runs in over the sun visor. I called the dealership yesterday and they are going to try and get a ford engineer to come and see if they can figure it out this time. I just wanted to check and see if anyone else had a similar water leak and got any resolution?
Thanks in advance for your comments,
Brian

TK1215

This is a known and well documented issue. Advise your dealer service person. There is a TSB on file for them to fix the issue.

Blfranks

A different TSB, other than the new header seal? That was the only one out for that issue that I knew of, but will check with the dealer

Jakob1972

Water leaks can be hard to track. Because the leak could be in one spot but the water travels to another location where you finally see it in the vehicle. It Would make sense to check the header area for the leak but it could be coming in at the back of the panel and rolling to the front where it can breach the seal and come in. I had a car once that had water in the front passenger floor board was wet but not every time it rained. I checked the windshield and passenger window nothing. Then one day it rained and the car was parked in the drive that had a down hill slope and it leaked, but didn’t leak if I parked it at the bottom of the drive where it was flat. Turns out it was a seal on the passenger tail light that was missing water would come in through the light into the trunk and run into the cabin and pool in the front floor board. I chased that leak for almost two years before I finally found it.