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Discussion Starter #1
Well, the YJ sat out in the rain yesterday and when I got in it, there was water dripping on the passenger side of the hump (line-x'd floor makes it easy to spot) and the stereo was crapped out again from getting wet.

I checked the vent intake on the cowl, drain is nice and clear, even removed the hose and doublechecked that. Windshield-to-cowl "hinge seal" looks just fine...but is there a good chance that's the culprit? Windshield gasket itself (glass to frame) is bone-dry, nothing coming from as high up as the softtop... The only other thing I noticed was, the screws that hold the cowl vent intake grille on (I think there's 8 of 'em) don't grab the sheetmetal all that tight - could water be getting in thru the screw holes?

I'll probably spring for a new hinge seal anyway - it's a 92 with nearly 150k on it, I'm sure it won't hurt, lol. I just hope I can get all those torx screws out to fold the windshield..... I was planning to just get one from Jeep - is there an upgraded aftermarket seal available though?
 

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that sucks. i left my jeep outside over night with out the top on. it rained that night and my stereo was fine, but my amp got soaked. good post.. u had reminded me about my amp.. i got the money now to replace it. CHEERS!
 

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Well, the YJ sat out in the rain yesterday and when I got in it, there was water dripping on the passenger side of the hump (line-x'd floor makes it easy to spot) and the stereo was crapped out again from getting wet.

I checked the vent intake on the cowl, drain is nice and clear, even removed the hose and doublechecked that. Windshield-to-cowl "hinge seal" looks just fine...but is there a good chance that's the culprit? Windshield gasket itself (glass to frame) is bone-dry, nothing coming from as high up as the softtop... The only other thing I noticed was, the screws that hold the cowl vent intake grille on (I think there's 8 of 'em) don't grab the sheetmetal all that tight - could water be getting in thru the screw holes?

I'll probably spring for a new hinge seal anyway - it's a 92 with nearly 150k on it, I'm sure it won't hurt, lol. I just hope I can get all those torx screws out to fold the windshield..... I was planning to just get one from Jeep - is there an upgraded aftermarket seal available though?
Replace your cowl seal!
 

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Discussion Starter #4
By cowl seal, I assume you mean the one at the windshield hinge. I have a new one sitting in the garage, waiting for me to move stuff out of the way so I can get the Jeep in and strip some torx screws, lol.
 

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yep its the cowl gasket they dry out and look fine but its the culprit...(me 2)
 

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Discussion Starter #6
Yep, got the windshield folded (only had to heat up and cut out one of the bolts!) and the center two or three feet of the dashboard sheetmetal is totally rusted out. The tub appears to be just fine, it's just that thin piece of sheetmetal that holds the dash and speakers. My cowl seal is also very porous - the new one I got from Jeep is 'regular' rubber. Maybe the Jeep has an aftermarket one on it? Dunno, doesn't matter.

Scraped the scale, vacuumed the pieces, let it dry overnight. I have to get kerosene for the garage heater, and I plan on using POR-15 on it once the garage is warm enough for it to dry properly. My guess is, even if the seal was good...water was getting in between the rust and the sheetmetal, even if the seal between gasket and rust was good. A nice solid coat of POR-15 should take care of it. I love that stuff :)

Seal install question: has anyone ever siliconed the front part of the seal (the part that reaches up the windshield face) to the sheetmetal? Just wondering if maybe water dripping behind that part, and collecting at the bottom of the windshield, contributes to deterioration and leakage...
 

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Discussion Starter #7
Well, this b**ch isn't gonna leak ever again.

Brushed on POR-15 all over the top of the tub, where the cowl seal sits.

Used POR-15 tube sealant (to quote Ron White: "it's a kit") to seal the rusted edge of the dash sheetmetal to the tub, and keep water out. Used the same sealant to seal the dash sheetmetal to the dashpad plastic, just to be safe.

Installed the new rubber seal on the bottom of the windshield frame (which was pristine, no rust or a mark of any kind on it).

....and for the overkill department, I took an old plastic "for sale" sign and turned it into a shield for the top and sides of the stereo. Even if water does come in, it'll have no way to get to the stereo.

<sigh> Now I just need to wait for the stuff to dry. Damn unheated garage, this'll take a while.....
 
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