Ford Explorer Quiz
Body and Paint

Diagnosis and Testing - Body System

In this manual: Body and Paint
General Information — 41Chassis — 173Powertrain — 250Electrical — 303Body and Paint — 331
~9min read

Symptom Chart

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Dust and Water Leaks

Most dust and water leaks are caused by missing or incorrectly installed body sealer or components. The leak source is located by:

  • pressurizing the vehicle and checking with soapy water.
    • Locate and seal body ventilation openings.
    • Turn the blower motor to HI.
    • Turn off recirculation.
    • Close the windows and doors.
    • Open the hood and spray soapy water on body seams and grommets. Be sure to check the areas around the front fender-to-cowl and hood mounting location.
    • Check for bubbles.
  • inspect for traces of dust or water near and above the area in question.
  • remove any trim or carpet in the general leak area.
  • road tests or water tests of the vehicle.
  • place a bright light under the vehicle, remove any necessary trim or carpet, and inspect the inside of the body for seams and weld lines.

Wind Noise

Most wind noise leaks occur at the corners of the windows or at the doors. Wind noise is detected while driving the vehicle at highway speed or at the speed specified by the customer. The vehicle must be driven in 4 different directions with the windows closed, the radio off and the A/C blower motor off.

Squeak and Rattle

Squeaks and rattles are usually caused by loose parts, contact, or relative movement between two surfaces, or by loose wires and connectors. The noise source can be located by stopping the movement of the suspected part by hand, or by using damping materials or low-friction materials.

Symptom Chart: Body System - General Information

Condition Possible Sources Action
Wind Noise/Draft and Water Leak at Door Perimeter Loose Seal CLAMP the seal holder to better retain it on the seal flange.
Seal Improperly Installed REINSTALL or REPLACE the seal, as necessary.
Door Misaligned ADJUST the door. CHECK the door gaps and fit to the door opening and ADJUST as necessary.
Refer to: Front Door Alignment (501-03 Body Closures, General Procedures).
Refer to: Rear Door Alignment (501-03 Body Closures, General Procedures).
Sill Trim Improperly Installed REINSTALL the trim.
Seal or wiper strip retainers damaged INSTALL new seal/wiper strip retainers.
Sheet metal seams in door or door opening SEAL leaking with seam sealer.
Integrated window regulator and foam seal damaged or out of position. REPOSITION or REPLACE seal.
Integrated window regulator and bracket fasteners not fully installed, missing or damaged. REINSTALL or REPLACE fasteners.
Window regulator components loose, missing or incorrectly installed. REINSTALL or REPLACE components.
Draft/Wind Noise and Water Leak Around Glass Run Door glass out of position ADJUST door glass.
Glass channel incorrectly installed or not fully seated REINSTALL glass run.
Refer to: Front Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Front Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Water leak path past glass INSTALL foam rope behind glass run.
Glass channel spread open PINCH glass channel to reduce opening size.
Glass run damaged INSTALL new glass run.
Refer to: Front Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Front Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Glass overlapping at corners, forming wrinkles REINSTALL glass run. INSTALL new part as necessary.
Refer to: Front Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Front Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Inner glass run opening edge not contacting sheet metal REINSTALL glass run. INSTALL new part as necessary.
Refer to: Front Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Front Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Glass Run and Bracket (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Refer to: Rear Door Upper Glass Run (501-11 Glass, Frames and Mechanisms, Removal and Installation).
Inner belt line overstuffed, creating gap between glass and weatherstrip REINSTALL inner belt line and INSTALL foam rope behind inner edge of glass run on belt line. INSTALL new glass run as necessary.
Draft/Wind Noise and Water Leak at Inner Belt Line Belt line seal incorrectly installed on flange ADJUST seal (do not kink flange).
No contact with side glass ADJUST door glass.
No glass contact at both ends of belt line seal. ADJUST belt line seal or ADD foam at ends of seal.
Belt line seal damaged INSTALL new seal.
Draft/Wind Noise and Water Leak at Outer Belt Line Weatherstrip Belt line seal incorrectly installed on flange (no glass contact) ADJUST seal.
Belt line seal not contacting glass ADJUST door glass.
No glass contact at both ends of belt line seal. ADJUST belt line seal or ADD foam at ends of seal.
Belt line seal damaged INSTALL new seal.
Draft/Wind Noise at Inside Door Handle/Speaker Opening Hole in weather shield SEAL hole with suitable tape.
Weather shield out of position ALIGN weather shield. INSTALL new weather shield if pressure-sensitive adhesive fails.
Outside door handle seal out of position/damaged ALIGN or INSTALL new seal as necessary.
Speaker or speaker seal missing or damaged REPAIR speaker seal or INSTALL new door speaker.
Wind/draft noise and water leaks at floor pan and grommets Missing or damaged plugs/grommets CHECK plugs/grommets for correct installation or damage. INSTALL new plugs/grommets as necessary.
Road noise Missing mastic insulators CHECK for missing mastic insulators.
Missing body insulators CHECK for missing body insulators.
Body/Door and Instrument Panel Creak Loose wires/cables CHECK that all wires/cables are routed correctly and inserted into the correct retainers.
Loose objects/components in door cavities, body pillar trim panels CHECK doors by lightly tapping with a rubber mallet under the door while listening for rattles in doors and pillars. REMOVE or TIGHTEN objects/components.
Buzz from instrument panel components IDENTIFY which instrument panel components are buzzing. SECURE/TIGHTEN components as necessary, ADD foam or felt as necessary if noise persists.
Door Drain Holes Collecting Water Drain holes clogged with dirt or road tar CLEAN drain holes of foreign material with a probe or screwdriver. CHECK drain holes regularly.
Wind Noise from Outside Rearview Mirror Outside mirror housing shifted REALIGN with edges overlapped for airflow, without gaps.
Mirror sail gasket bent/shifted REINSTALL, turning over and correctly aligning gasket.
Mirror housing plug incorrectly installed REINSTALL with edges overlapped for airflow.
Sail panel inner trim incorrectly installed INSTALL sail panel trim. ADJUST door trim.
Sail inner gasket/barrier incorrectly installed REINSTALL trim cover, correctly aligning gasket/barrier.
Air path through wiring harness/fastener openings BLOCK air paths with foam/tape.
Open fastener hole in mirror housing/sail INSTALL new cover if missing.
Mirror housing trim cover flush with housing, causing whistle INSTALL new outside mirror.
Refer to: Outside Mirror (501-09 Rear View Mirrors, Removal and Installation).
Knock/Vibration from Outside Rearview Mirror Mirror mounting nuts loose TIGHTEN mirror mounting nuts.
Refer to: Outside Mirror (501-09 Rear View Mirrors, Removal and Installation).
Aftermarket air deflector / rock shields If possible, REMOVE the non-original air deflector/rock shield, then perform a ROAD TEST. If the concern is no longer present, INFORM the customer that the aftermarket component was the cause of the concern.
Draft/Wind Noise and Water Leak Around Fixed Glass Perimeter Air rises up the windshield molding along the front pillar INSTALL the foam rope along the entire length of the front pillar.
Gaps in the windshield/backlite sealant bead Install a new windshield/backlight.
REFER TO: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
Windshield/backlite is shifted or incorrectly installed Install a new windshield/backlight.
REFER TO: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
Hood rear seal at the base of the windshield is shifted/damaged ALIGN or INSTALL new seal as necessary.
High Mounted Stop Lamp CHECK the high mounted stop lamp seal. REPAIR or INSTALL as necessary.
Application on the front pillar along the windshield rise CHECK the attachment clips for damage and RE-INSTALL the component. INSTALL a new component as necessary.
Draft/Wind Noise and Water Leak at Rear Door/Liftgate Perimeter Loose Seal JOIN the seal carrier to improve retention on the seal flange or INSERT foam into the carrier.
Seal is shifted or incorrectly installed RE-INSTALL the seal.
Liftgate/cargo door is misaligned ALIGN the liftgate. CHECK that the liftgate fits the body opening and ADJUST as necessary.
REFER TO: Rear Liftgate Alignment (501-03 Body Closures, General Procedures).
Sill plate is shifted REINSTALL the trim.
Seal or wiper strip retainers damaged INSTALL a new seal or retaining clips.
Wind noise/water leak or noise from the roof opening panel Sunroof panel/components Refer to the Symptom Chart: NVH for diagnosis.
REFER TO: Sunroof (501-17 Sunroof, Diagnosis and Testing).
Wind Noise Generated by Airflow Over or Around Body Panels Fender splash shield is misaligned RE-ALIGN the fender splash shield.
Body panel is shifted (exposed edge) ALIGN the affected body panel.
Hood is shifted (front gap) CHECK the hood gaps and fit. ADJUST the hood as necessary.
REFER TO: Hood Alignment (501-03 Body Closures, General Procedures).
Front grille edge noise APPLY foam into the recesses behind the louvers.
Wind Noise Generated by Grille Opening Panel Grille contacts the leading edge of the hood If possible, ADJUST the grille panel forward to eliminate wind noise.
Sharp edges due to material defects REMOVE the sharp edges (without visible surface damage).
Wind Noise from Vent Outlet (Body Vent) Vent housing is incorrectly installed REINSTALL the air extractor housing.
Vent housing or flap is damaged INSTALL a new exhaust fan.
Wind Noise from Bug Shield/Outside Windshield Sun Visor Turbulence caused by location and shape DETERMINE whether the component is an Original Equipment Manufacturer (OEM) part or an aftermarket part. If aftermarket, ADVISE the customer accordingly. If OEM, CHECK the installation for correctness. If the noise is abnormal, REPAIR or INSTALL a new component as necessary.
Wind Noise from Hood Panel (Sheet Metal Screen) Rubber edge of the sheet shield does not contact the windshield RE-INSTALL the component. If the component still does not fit, CHECK the attachment clips for damage. INSTALL a new component as necessary.

Test yourself

A quick Ford Explorer quiz: every answer comes with an explanation and a link to the manual page.