windshield gasket leaking into top passenger side of cab advice please.

After taking all the interior panels, carpet, and the ceiling out of my taco I can finally get a good look at where the water is coming in. I also took of the rooftop trim gasket.

If I point a hose at the corner of the windshield gasket on the passenger side water pours into the truck at a windshield clip about six inches from the passenger side window.

I can not see exactly how this is getting in but suspect a problem with the windshield molding.

I think there may be some rust under that molding on the drivers side as well.

I was wondering if I can just pull this window gasket out. address any rust, and replace it with a new gasket without having to remove the windshield...

And if I can does anyone happen to know what the part number is and perhaps the procedure and materials to replace it? (2006 extended cab)

Here is a pic of the where the water gets in followed by a pic of where the water comes out and into the cab:

 

It looks like the windshield urethane that seals and secures the windshield to the truck failed, unfortunately replacing just the rubber seal around the glass won't fix the issue if water is getting in. I would have the windshield pulled and check the metal underneath for rust and then have it reinstalled properly. We've had a few cars come to our shop with rusted windshield frames from improperly installed windshields. It's usually bare metal left under the glass that creates the rust & leak issue.


Example of how it can spread

 

That is my concern.
My windshield is cracked anyway. I was thinking I should pull the windshield myself and clean it all up then have someone come and do the install...
Perhaps I will talk to a local shop first and see.

Thanks for the heads up.

 

Here is what I found after pulling off the moulding that runs all the way around the top three sides the windshield:

I believe that after the windshield is installed and secured, and before the moulding is pressed into place, a protective sealant is supposed to applied all the way around (correct me if I am wrong please).
After washing away all the silt and crap that had accumulated under the moulding I found several nice runs of a black sealant which came up shiny and clean but much of it was missing and much of that was rusty.
Spots around the windshield without green had no sealant:


Perhaps the hopper in the factory ran dry and they did not correct it.
If it was replaced before I bought it the person who replaced it was a real big wiener.

also... Is the windshield moulding necessary? does it play a role in supporting the windshield? or is it just aesthetic?

What I did:

- scrubbed with firm brush and degreaser then rinsed.
- removed rust and paint bubbles with dremmel and thin wire brush then rinsed.
- scrubbed with firm brush and CLR.. let sit for half hour and rinsed.
- scrubbed with firm brush and degreaser then rinsed.
- dried thoroughly with paper towels and hair dryer.
- let sit over night with big fan and heater going inside cab.
- taped and covered the windshield and truck against over-spray then sprayed a coat of rust reformer on any areas I had removed rust from
- let the rust reformer sit for about thirty minutes then
- applied Lexel Multi Purpose Sealant in a thick bead.
- using a piece of grey foam backer rod slightly thicker than the channel around the windshield, starting at the bottom corner on the drivers side, pushed the foam firmly into the channel and pulled it all the way around the window forcing the sealant into any crevices and ensuring a nice bond with everything in the channel... it also ensured a nice consistent coverage and smooth finish.

I have no more windshield leak. It looks nice. I may order a replacement moulding... if I have to.



Thanks to all those who offered suggestions and advice.
I will post a picture of my fix tomorrow if weather allows for a decent shot.

 

So I have to get better at this before and after thing. I tend to launch right into the work and forget I am trying to share my experience until it is too late.

I only got one before shot of the corner of the windshield and it had the moulding on. so for what it is worth here is a before / after shot of the corner and and after shot of a larger portion of the area I repaired:



You will have to take my word when I say this shot would have been mostly rust before I fixed it.

 

Looks good! I’ve had several electrical issues that I suspect originated from windshield leaks, but my plan is to get the windshield replaced by insurance (think my policy allows every other year replacement). My glass is now 9 yrs old and pitted pretty bad. I’ll bring cider doughnuts and coffee for the shop and hang out to watch the process…usually confirms a proper replacement. Thanks for the write-up.

 

I am very on board with the cider doughnut diplomacy it is a great idea.
Depending on the shop they may not let you into the building to watch the process and cite insurance policy... so pick a nice day and see if they will do it outside.

I am glad you liked the write-up. I get quite a lot of help from this forum so this is my attempt to give back. It also gives more experienced people a chance to catch me making mistakes and address them.