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924inVA · Joined: 07 May 2008 Posts: 11 Location: Northern VA

I just purchased my 1987 924S about a week ago. It had just rained, and I noticed at that time that the passenger footwell carpet was moist, and knew I had a slight leak somewhere.

Fast forward to today - It's been pouring rain here in Northern VA for 2 days, and this morning I got in and found a half inch puddle in the rear passenger footwell.

There is no obvious signs of a leak. I don't have a sunroof. The headliner is not wet, the rear seats are not wet.

Can anyone help with a place to start looking, or how to resolve this issue?

Smoothie · Posted: Fri May 09, 2008 11:55 pm Post subject:

Battery tray leaks are common - that would account for the wetness in the front passenger footwell. If you were parked with the front higher than the rear, that would account for the puddle in back as well.
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"..it's made in Germany. You know the Germans always make good stuff."

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Eturbo924 · Joined: 09 Nov 2002 Posts: 2212 Location: Londonderry NH

The other obvious... well not so obvious some times... is the rear hatch seal. They frequently get pinched and wear out at the top corners. Just outboard of the actual hinge point.

Mine failed there and the water tracked down the rear pillar burned out the passener speaker and damaged the rear quarter interior trim. Also caused the rear passenger floor to be damp.

I figured the usual suspects ... battery tray... sunroof seals... but nope... turned out to be the rear hatch seal.

Inspect it closely for proper fit and any wear... but also of course inspect the battery box! If that is the case you need to nip it in the bud before it gets much worse.

I have also seen front windshields leak but that is less common and only when a poor replacement has been done.

Eric
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924inVA · Joined: 07 May 2008 Posts: 11 Location: Northern VA

I haven't had a chance to check out the battery tray, but I will this weekend.

I did inspect the hatch, and as expected, it's begun to separate at the passenger side near the roofline.

What are the possible solutions if its the hatch? What about the battery tray?

Smoothie · Posted: Sat May 10, 2008 7:28 am Post subject:

Here's a serious battery area rust problem and the extensive repair to fix it (31 pics starting with this one) - <click>

If the problem is less severe, I'd scrape out all the seam sealer in the area, clear out any loose rust, sand some and clean (I'm also in the habit of using a phosphoric acid-based metal prep at this point), then clean again, and give it a couple coats of POR-15, then replace the seam sealer with new over that.
POR-15 needs a rough surface to adhere to (preferably actual rust or "seasoned metal", but sand-blasted or chemical-etched surfaces are ok).
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Eturbo924 · Joined: 09 Nov 2002 Posts: 2212 Location: Londonderry NH

on the rear hatch are you talking that the glass is coming away from the frame?

I was talking about the seal that is the rubber style between the hatch and the car.
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1982 924
1992 968
2003 C4S
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924inVA · Joined: 07 May 2008 Posts: 11 Location: Northern VA

Okay, after a little research I think I've determined that it is the battery tray area.

I figured it out when after a nice long night of rain, I made a right turn and watched a significant amount of water pour into the passenger area footwell.

What are my next steps to fix this problem?

Rasta Monsta · Joined: 12 Jul 2006 Posts: 11733 Location: PacNW

The first step is to take it into a body shop. When my NA leaked in this area, it was body putty/seam sealer which had dried out and fallen out. They re-puttied the area very inexpensively.
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WeiBe (1987 924S 2.5t) - 931 S3

Eturbo924 · Joined: 09 Nov 2002 Posts: 2212 Location: Londonderry NH

No... the first step is to go under the hood of your car and clear the drains for the battery area and the area around the windshield wiper motor.

Sounds like you are allowing the water to build up then when you go around a sharp corner the water washes up and over the area that the cabin air intake fan is. The water can come right in that way.

I had this happen back when I was 17 and yikes it is strange to all of a sudden have water splashing on your feet when going around a right hand corner!

Then I would pull the battery and inspect the battery tray area... but sounds like you might be in luck and not have a perforation yet... if the water is only coming in when you go around corners that is.

Good luck
_________________
1982 924
1992 968
2003 C4S
Parts Parts Parts and More parts.
E-mail me for parts you need!
Drive Fast!

HEMBRANT12 · Joined: 28 Dec 2007 Posts: 20 Location: Grapevine Texas

Anyone have any ideas as to where water could be getting in through the driverside floor? I've already checked the drain tube from the windshield wiper well, and it is in good shape with no rust. I got a buddy to spray water in there while I watched from inside it seams to be coming from up above the clutch pedal somewhere, but I can't seem to track it down. It's a steady drip in a hard rain. Anyone have this leak?
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Smoothie · Posted: Tue May 20, 2008 10:55 am Post subject:

HEMBRANT12-
There's a metal drain tube in that area to let water out from the wiper motor area. -But it's supposed to dump the water out the front side of the firewall, into the engine compartment. You might have some corrosion working on the inner (passenger compartment) end of the drain tube.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

When I had the same problem with water splashing my feet, I found that one of the rubber sleeves that the wiring harness pass through (driver's side firewall) had hardened and let water in there. Look right under the drain hole from the washer motor area and you may find yours cracked too. When water would drain out the hole, it would find it's way back in through the cracked rubber. It would happen mostly when I came to a stop. Put a new one on and presto! Dry feet!
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'77 1/2 924 N/A- 5 speed Audi box
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