tech did a 2000 ford excursion windshield 3 weeks ago. customer said it was pouring in water. tech went back and pulled the windshield out and everything looked good. he found a gap/pin hole in the body seam on the upper drivers corner. "was never like that before" attitude from the customer. weren't there problems with these older fords with the body seams.

there have always been problems with them. been there too many times to count

so...how do you repair the seam

Any chance of your tech removing sealant that actually covered the existing pin hole?

Most famous Ford screw-up was the water leak around the F-150 hood hinge weld seam. How many GEM modules were ruined by water intrusion? I would do 20-30 a year out of a single Ford dealership. Bad windshield installs would also open up the seam, it seemed. I would use urethane and primer to seal up the seams without comebacks

Not too mention the Carlite glass frit would disintegrate and cause the glass to come loose from the urethane. Had Ford dealership want us to R&R these and we would sell them a glass because of frit failure, awesome moneymaker!