98 Grand Caravan - rear hatch water leak

[zky]

I had multiple water leaks near the rear hatch of my GC. I took the carpet up, and took all the side panels off to find one near the baffle or vent behind the wheel wells. I fixed that leak with a sealant, but now I have a leak up top by the hatch that I absolutely cannot find the origin. I have removed and resealed the weather stripping around the hatch twice and I'm certain it is not coming in there. The leak is actually coming through some holes in the sheet metal under the horizontal plastic trim piece at the top of the hatch opening (interior to the vehicle of course) near the corner of the hatch opening on the driver's side.

The only place I can think that water could be getting in between the sheet metal in the roof would be on the seals that run forward and aft on the roof of the vehicle where the roof sheet metal meets the side panels. I don't have a luggage rack up there but they still have these black plastic runners in the grooves.

Anybody else have any experience like this with there minivan? Any and all suggestions would be greatly appreciated. The vehicle only has 32k miles on it, and I was hoping to keep it for awhile, but not if I can't fix the leak. I'll trade it in on an Odyssey if I have to.

Thanks.

[scottw]

Mine leaked from the rear hatch from the day I picked it up, and the dealer could not find the source. I brought it back 4-5 times, then started attacking the vehicle with sealant.

The last seam I sealed before the leak stopped was right along the top of the hinges for the hatch. Try placing a bead of caulk along the top of the hinges where they join car.
Scott

[Theadius]

Any feedback on what you found? Have you fixed the leak? What fixed it? My 96 Grand Caravan just started leaking water in the rear hatch area and it appears to be coming from the rear hatch or the side vent windows. The water actually runs in through the rear speaker vent on the driver's side.

[scottw]

It no longer leaks, try the bead of caulk along the top of the hatch hinge.

Scott

[Theadius]

Looking for feedback from zky also.

[zky]

It hasn't been warm enough to caulk the hinge yet. It's suppose to warm up this weekend and I'm going to do it then. I'll let you know if it works or not.

[Theadius]

I have the same leak - water is coming through the holes in the sheet metal above the horizontal plastic trim piece at the top of the hatch opening (on the drivers side of the van). I tried soaking the hinge points but that did not appear to cause any leaking. I am wondering whether the water is entering through the wiring grommets or the protective boots on the wiring harnesses that run in each side on the upper hatch area. I have to wait until the area thoroughly dries before I check this.

[Theadius]

Ok zky, we have had two beautifiul weekends here in Florida. Have you had a chance to work on your leak yet? Any feedback?

[cindywhitall]

I too have a leak in my caravan. Of course water leaks are not covered under the extended warranty. We found the leak, both side leak in the hinge area. There is a little strip of metal that wraps around to the inside from the top lip of the opening. Between the weatherstriping and the roof there are some little impressoins. THe water settles there and then somehow leaks thorugh to the inside. It travels along the top of the door and down the inside of the plastic panels where it comes out on the floor in the corners. I had no idea it was more than a tiny bit wet in the corners until I kneeled on it late in the fall and my knee got wet from a carpet that looked dry.

One day I tried to peel up the carpet because I felt a hard lump. Turned out it was ice!! My padding had been soaked and in the freezing weather it froze. The padding ripped as I tried to pull it up. Now we have finally had a thaw and I tore apart the plastic around the door and found the leak source. We pulled up the carpet and it is soaked up to just behind the middle row. The carpet feels dry on the topside, but the pad is drenched. We are going to seal up the suspected leaky area, but now I don't know what to do about the carpet. It does smell musty and is not drying too fast. It is like layers of wet towels. I may rip off the padding (it is attached to the carpet, which is rubber backed) and replace it with HOme Depot's best carpet padding. I don't want to replace it all, but I am afraid it will take a month to dry and grow very moldy. Any ideas?????

I have a photo of the spot in case there is a way to post it or if anybody wants me to email them.

[zky]

OK. I finally caulked the hinge, but now I'm waiting for rain. I still don't have my hose hooked up yet because we're suppose to go back down to about 30 degrees next week. Sorry, I'll update the post as soon as I confirm I have fixed, or not fixed the problem.

By the way, caulking the hinge was NOT an easy job. I couldn't figure out how to get the caulk into the tight space without taking the hatch off. I unbolted the hatch from the hinges and moved it back just enough to caulk it. Man, that hatch is heavy!!! Make sure you have some help, and a couple of 6' boards to use as props.

If anybody has a better way of doing this, please share it. My way, as always, is probably not the best!

[zky]

Ok Theadius, here it is, and I'm sorry it took me so long to get this information posted (busy, like everyone). Well the first caulking didn't work completed. I caulked the top and two sides of the hinge with a caulk that adheres to metals. It slowed the leak, but it still leaked. At least I knew I was in the right area. I then caulked the bottom AND around all three bolts that mount the hinge to the body. I only did this a couple of days ago, but I left the van out yesterday when it rained all day and there was NO LEAK!!!! I think I may have it beat. My advise, caulk all around the hinge, and over the bolt heads. I just hope I never have to take the bolts back out, because getting the caulk off enough to remove the bolts will be very difficult. Good luck!!!

[scottw]

Zky - Glad it worked for you.
Mine has begun to leak a little so I think my caulk job needs to be redone, its been almost a year. I discovered something odd that perhaps you should take note of.
If I close the hatch with all the other doors and windows closed it will leak, if a close the hatch with another door open it will not leak. I think that the door cant seal right when its trying to force all that air into the car, that or all the escaping air messes up one of the door seals.

Scott

[Theadius]

Ok zky - thanks for the info. I applied a strip of duct tape to the gap across the top of the rear hatch between the hatch and the body of the van and that stopped the leakage so I know that the problem is somewhere near the top of the hatch. Hopefully I will get a chance this weekend to try caulking. By the way, what kind of caulk did you use?

[zky]

I think I used a neoprene caulk, but I really can't remember. Just go to your local home improvement store and buy a caulk that states on the label that it will adhere to metal. That's all I really cared about.

That's a very interesting observation that Scottw made. I think I may have to do a little experimenting with mine in that regard. Of course, it's 40 degrees here again, so I'll wait a little while. Let us know if you find anything else interesting in your experimental testing Scottw. Thanks.

[scottw]

I found it. I think water was coming into mine from a couple different spots, but I finally eliminated all leaks. The last spot I hit with caulk was the seal around where the windshield washer tubing enters.
I think that by closing the hatch and forcing all that air into the vehicle, the air rushing out forced that seal to fail. It would only leak if I closed the hatch without opening another door first to let air escape.

I bought this car new in 1999, its taken 5 years to find and fix (2) different water leaks.
Woo hoo!