aowRS

I've noticed a dark area for some time in the carpet right next to the door sill. I thought it may have been an old stain from spilled coffee - but it's definately damp to the touch.

Any thoughts?

- I purchased the truck new - it now has 331,000 miles
- I occasionally add some refrigerant to keep the A/C cool
- The A/C does drip condensate on the ground
- Coolant level is fine
- No sunroof
- Original windshield
- No accidents






Andreas

aamsowens

Check your clutch fluid my 87 leaked there

aowRS

It's an automatic.



Andreas

wyoming9

iTrader: (1)

If it is a Automatic it is either brake fluid or water coming in .

Losing any brake fluid??

leak in the windshield seal ??

Hole in the floor some place behind the left front wheel??

A really bad engine oil leak I am sure you would notice That is migrating into the cab

aowRS

It's not brake fluid and the windshield & seal are original. After finding a few other threads describing a similar issue, I will take a closer look at the large firewall grommet. I've sent various wires through it over the years for lights, sensors, etc., so it could very well be the culprit.



Andreas

aowRS

I believe I may have solved the mystery. This morning I removed the sill cover and then folded the carpet back towards the shifter. After vacuuming a bit I noticed staining in the area of the footrest. This staining continued to the floorboard and along the side, where the carpet & padding was damp.

I took a closer look and was surprised to see a Y-shaped crack in the sheet metal of the foot rest. Shining a light on the crack made it very visible in the wheel well. My theory is that the foot rest fatigued & cracked (it flexes very easy) which then led to the fender well underseal cracking. Driving in the rain would keep that area hosed down with water. Furthermore, I tend to run the truck through a touchless car wash with chassis spray quite often...

I have made a cardboard template and will create a plate from 1/8" aluminum to cover the entire footrest and prevent further flexing.

Instead of trying to remove the entire carpet, I'll try to clean it in place and leave it folded up for a week or so.












Andreas

aowRS

Almost done. I created a reinforcement from 1/8" aluminum plate, treated the rust, and then attached the plate using some stainless steel buttonhead bolts, washers, and lock nuts. I bedded the plate in OSI polyurethane construction adhesive.

Bush league, but hopefully solved.








Andreas

wyoming9

iTrader: (1)

Hole behind the left front tire Who would have ever thought??

It Does not hurt to put something on the outside as well

Unless you don`t drive in the snow.

aowRS

You called it. I did apply gutter sealant to the area around the crack (in the wheel well).

On the inside, some etch primer followed by a dusting of Dorado Gold (left over from a project)









Andreas

Rock Slide

iTrader: (1)

Glad you found it.

You were right to go towards the firewall grommet...that has caught many by surprise.

aowRS

Since everything was dusty under there, I looked for any signs of water running down from either the grommet or the wires that go through it. Everything seemed dry.

I'll keep an eye on it and update this thread with my findings in a few weeks (or months).



Andreas

PODrs

?????

avalonracing

As always, nicely done.

pwgarcia

I have this same exact prob with my 04 Toyo Tacoma Dbl Cab. Has 138,000 mi and I intend to get much more. Thanks for this awesome post as I intend to try a similar fix. THANK YOU!!

aowRS

The sheet metal of your footrest cracked as well?

For the record, my carpet & padding have remained dry, despite a few carwashes, and numerous drives in torrential downpours.



Andreas

pwgarcia

I'm not exactly sure of the extent at this time. This weekend I'll be pulling back the carpet to view the damage. All I know right now is that I can push my finger thru the hole in the wheel well and push the foot rest.

wyoming9

iTrader: (1)

Sounds like a bit more then a crack.

We want to see pictures of this!!

aowRS

Damn right!



Andreas

aowRS

It's been two years since my ghetto repair and the carpet has remained dry. Ghetto repairs FTW.




Andreas