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I recently had a factory TSB item taken care of for slight bubbling paint around my windshield. The dealer covered it under the 10-year rust warranty, and did a nice job. But the seal around the windshield at the bottom, driver's side near the pillar post, is dipping into the channel for about 6 inches. I can take a credit card and gently pull it back up so it covers the channel, but after a day or two, it collapses again. It's as if there isn't quite enough seal there to allow it to rest on the lip of the channel. Presumably, it's there to keep rainwater OUT of the channel, so I'm not thrilled that water's getting in. I can't imagine that there's any way that this seal can be repositioned without removing the windshield. Has anybody else had this problem? The car's going in for an oil service in a couple of weeks, but I don't want it to be one of those "we have to order a new seal" one-week affairs; if they're going to need a new seal, I want them to order it ahead of time. Any thoughts or suggestions?
I had exactly the same problem on my 96C4, which I purchased this year. Obviously, some rework had been done on the car, but I did not know the real history. Anyway, I decided to replace the windshield, due to pitting, etc., and my glass guy said that whomever had worked on the windshield had positioned it incorrectly, so as not to permit the seal to mate properly. Bottom line - u need the windshield replaced or reinstalled with a new seal.
I read your post and this is very odd, since this seal is designed to snap into a channel that goes around the windshield. If you look at the underside of the seal you can see a molded "arrow-head" that goes into this channel. The "arrowhead" snaps down into the channel and pulls the lips of the seal tight against the car's skin.
It's hard to get the "arrowhead" to snap into the channel properly on the front w/s seal, especially when you turn the corner at the lower pillar. It could be that the installer just missed the channel and the seal is bottoming out around the cavity surrounding the windshield. My guess is that this is the problem. The front seal (trim piece) is tough to install, takes some time and finesse and a spray bottle of soapy water to lube it up.
You can pull up the seal and take a look and see if this is the case. If the seal is not ripped or torn and the "arrowhead" underneath is in good shape, there probably is just a problem with the install. It's also possible that the channel around the windshiled was damaged or mangled during the paint repair, but I think this is a sturdy metal channel. The rear window channel is plastic and cracks, causing a problem with the seal laying flat.
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