I got real ambitious the other day and decided to vacuum out my truck since it had been a couple of years... ha! Upon removing my Husky Liners I found my driver's side carpet to be wet. I immediately went into "OCD I'm gonna fix it" mode. I hopped online to C-Fans which I used to frequent when I first got the truck only to find that it is all but dead. After much search between there and here and google all I could find was information going back to third brake lights and issues with some of the early models and lack of seam sealer at the firewall/cowl.
I first ripped up the carpet and padding. Found water pretty much everywhere, and dried it up the best I could. Got the garden hose and ran water over the roof of the truck toward the engine bay and cowl and immediately found water entering the cab around the driver's kick panel behind the parking brake assembly. At this point, I removed the wipers, antenna, and cowl to find no conclusive evidence. Next, I removed the driver's side wheel well. I knew that if I poured even a small amount of water into the cowl on the driver's side, I would get water into the cab. After removing the wheel well I slowly sprayed the hose on all the seams inside the wheel well starting from the bottom and working my way to the top and did not get any water into the cab until I sprayed from the fender well into the cowl. At this point, I determined the leak, hole, whatever to be behind the fender and in the cowl but somewhere I'm unable to see with the fender on, so I removed it. At this point, the source of the leak was fairly easy to spot. You could easily see that the seam had never had any sealant on it. Where the seam is, is right next to where water would drain from the cowl into the fender. That area had built up just enough dirt/crud to back up water toward the seam and thus into the cab.
I cleaned out the small amount of crud and thoroughly dried the leaking seam. After a little bit of cutting, I was able to reach the seam with some auto/marine grade silicone rtv and seal her up. I put Humpty dumpty back together, tested with the garden hose the next day (after it rtv had cured) and all was well.
This seemed to be a very obscure leak and I had found nothing of it anywhere in my searching so I figured it would be best to post it up and hope that it may help someone else someday.
I first ripped up the carpet and padding. Found water pretty much everywhere, and dried it up the best I could. Got the garden hose and ran water over the roof of the truck toward the engine bay and cowl and immediately found water entering the cab around the driver's kick panel behind the parking brake assembly. At this point, I removed the wipers, antenna, and cowl to find no conclusive evidence. Next, I removed the driver's side wheel well. I knew that if I poured even a small amount of water into the cowl on the driver's side, I would get water into the cab. After removing the wheel well I slowly sprayed the hose on all the seams inside the wheel well starting from the bottom and working my way to the top and did not get any water into the cab until I sprayed from the fender well into the cowl. At this point, I determined the leak, hole, whatever to be behind the fender and in the cowl but somewhere I'm unable to see with the fender on, so I removed it. At this point, the source of the leak was fairly easy to spot. You could easily see that the seam had never had any sealant on it. Where the seam is, is right next to where water would drain from the cowl into the fender. That area had built up just enough dirt/crud to back up water toward the seam and thus into the cab.
I cleaned out the small amount of crud and thoroughly dried the leaking seam. After a little bit of cutting, I was able to reach the seam with some auto/marine grade silicone rtv and seal her up. I put Humpty dumpty back together, tested with the garden hose the next day (after it rtv had cured) and all was well.
This seemed to be a very obscure leak and I had found nothing of it anywhere in my searching so I figured it would be best to post it up and hope that it may help someone else someday.