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2002 gmc envoy_sle
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Discussion Starter #1
I had started this in another thread ~1 month ago, which had grew in size since then. I wanted this thread to have the correct title, and have the problem and solution in the first message.

The water leak I had would happen even in a light rain, and with the truck parked. Before I even moved the truck, I would notice a wet spot on the headliner above my (driver) head, about a half an inch round. Sometimes, after I back the truck up or turn out of the parking spot I am in, a few drips would come from the Overhead grill openings. Just a few drops, and then nothing (still, very embarrassing when you have company). I tried the drain tubes, and they seemed fine (lot's of threads here on drain tubes, so I will spare you the diagnostic details).
So one time, shortly after the rain stopped, I went out and looked inside the sunroof (before moving the truck) and here is what I found. I will leave you with the three pictures below, since one picture is worth a thousand words (especially when the picture has words on it :raspberry).

I hope this helps someone else fix their leaky sunroof / Overhead.
 

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2005 chevy trailblazer_ls
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:thumbsup:This should be a sticky! Very good job of showing pics with explanation!:thumbsup:
 

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2002 gmc envoy_sle
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Discussion Starter #4

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2003 gmc envoy_slt_xl
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well it is crazy you posted this on the same day I figured the exact same thing out!!!

I had pulled the headliner down just a tad on the drivers side and found the same evidence, but mine was not leaking as bad

great pics and post - we are having a pretty hard rain here in KY tonight/tomorrow so the "voy" sits in the garage drying out - will repair tomorrow STICKY THIS!!!

PS - I can get some other pics of the wire harness inside the headliner while the drivers side is still pulled apart let me know if it is worth posting some pics

thanks again for posting this
 

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2002 gmc envoy_sle
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Discussion Starter #7
I had pulled the headliner down just a tad on the driver’s side and found the same evidence, but mine was not leaking as bad.
It's a good thing you caught the leak before it turned into the mess that mine was.

Great pics and post - we are having a pretty hard rain here in KY tonight/tomorrow so the "voy" sits in the garage drying out - will repair tomorrow STICKY THIS!!!
I do not have a garage, so the truck had Green masking tape around the sunroof and the windshield for two days until I made sure the silicone dried up well. So far I fixed three water leaks: Roof rail, rear right corner; windshield, upper left corner; and the sunroof tracks. My truck should be the poster child (or truck :excited:) for water management. I didn't mind the tape. The least I could do for GM after all the trouble I went through to fix the water issues is drive around publicizing the fact their product leaked from pretty much everywhere :crackup:

PS - I can get some other pics of the wire harness inside the headliner while the driver’s side is still pulled apart let me know if it is worth posting some pics.
Sure, the more pictures the merrier. I should have taken one myself while my headliner was down. I don't know why I did not. :duh:
 

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2002 gmc envoy_sle
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Discussion Starter #9
Mine did the leaky thing five days ago. May try this fix today before the game.
Hopefully this fixes your truck too. Mine is still leak-free since I fixed it in December.
 

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2002 gmc envoy_slt
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Leaking Roof 02 Envoy

Thanks for that info as it is exactly what happened to my 02 Envoy. The water is finding its way into the overhead control panel and dripping onto the rear view mirror. Thanks to your pictures I could trace the dampness back to the source and now have to get some of that good black silicone sealer.

Living out here here on The Wet Coast, a sealed auto is essential!!
 

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2002 gmc envoy_sle
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Discussion Starter #11
Thanks for that info as it is exactly what happened to my 02 Envoy. The water is finding its way into the overhead control panel and dripping onto the rear view mirror. Thanks to your pictures I could trace the dampness back to the source and now have to get some of that good black silicone sealer.
Glad it worked for you too. I almost sold the truck, just due to the water leaks (I had three different leak paths.)

Living out here here on The Wet Coast, a sealed auto is essential!!
:laugh:
 

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2002 gmc envoy_sle
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Discussion Starter #13
I hope it helps. I fixed five different leak paths on my truck.:bonk:
 

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2003 chevy trailblazer_lt
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Headliner leak--no luck with recommendations

Thank you for the excellent post and discussion! Unfortunately, I have yet to isolate the root cause of my leak. As you will see from the pictures, the sunroof area on my truck is leakproof and I have opened it after a good rain and checked all rail areas...all dry. The pictures will show where my leaks originate, and also where I suspect the intrusion is coming from. Also note that the drips occur after the vehicle has been sitting on a level surface after rather substantial rain (we get a bit of it here in Germany). Also note that this problem did not occur until approximately 12 months ago (even in the torrential rains of Florida).

Any help is appreciated!

Rick
 

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2004 buick rainier
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ok so checked the tubes they are clear, then siliconed exactly like you did,went one step further and lubed the weather stripping around the glass with silicone spray, now we wait for rain!!! and hope it stays dry!!!! will keep you posted!!:)
 

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Discussion Starter #16 (Edited)
Thank you for the excellent post and discussion! Unfortunately, I have yet to isolate the root cause of my leak. As you will see from the pictures, the sunroof area on my truck is leakproof and I have opened it after a good rain and checked all rail areas...all dry. The pictures will show where my leaks originate, and also where I suspect the intrusion is coming from. Also note that the drips occur after the vehicle has been sitting on a level surface after rather substantial rain (we get a bit of it here in Germany). Also note that this problem did not occur until approximately 12 months ago (even in the torrential rains of Florida).

Any help is appreciated!

Rick
The best method to find a leak is to take the headliner corner where the leak is coming from down, and keep it down (you can use zip ties to hold in place) and wait for the rain. I had no trouble with the headliner assembly, but other members have had a rough time re-attaching the sun visor support. There are many threads on that. I believe I posted some pics on that in at least one thread out there. You can use a water hose instead of waiting for the rain.

My truck is the poster child for water leaks. The leak path I show in post 1 of this thread was not the only leak path I found on my truck. I also had a leak from where you suspect yours is coming from - under the top corner of the driver's side of the windshield. Mine, however, happened shortly after I had the windshield replaced. This leak path will cause water to puddle under the A Pillar’s plastic trim piece. The back of the trim piece has ribs, and the water will collect on it. This leak on mine never made it to the carpet of the truck. The water was not much and it would stay on the A pillar trim piece ribs until it dried. This possible leak path however will not explain the water dripping from the tiny hole in the sunvisor support on your truck (your pic #4), since your leak happens while the truck is parked on level ground, and even the highest point on the wind shield is still lower than the visor support, and the headliner at the front edge curves down. Gravity would rule out your suspect leak path as the culprit. For my truck, I removed the molding on the side of the winsdshield – The one that goes up and down on one side of the truck, not the one that goes across from the driver to the passenger side. The vertical one is screwed on. If you carefully move the weatherstrip out of the way, you should see the screws. I ran silicone on the top corner of the windshield (between glass and sheet metal) and that leak path to the A Pillar was fixed. It’s easy to remove the A Pillar trim to check for water on the ribs. The piece is only held on with clips. You can start from the top side and carefully pull it away with your hand – don’t use a lot of force.

My next guess would be the roof rail screws, specially the front one or two on the side your visor mount is dripping. Remove the screw and see if the screws are rusted at the tip. There are 6 screws holding each rail down to the roof, and thanks to a ‘brilliant’ design direction approved by GM, the holes in the sheet metal for the screws go all the way through, or atleast they do on 2002MY. You can take a screw out and look right down at the headliner. Atleast two of my screws were rusted all the way through to the tip. In my case, they were the rear ones, and the rear end of my truck also leaked water. So, all of my 12 roof rail screws now have white plumping tape on them, a tiny dab of silicone on the threads over the plumping tape, and generous amounts of black silicone covering the entire exposed screw head areas.

Another leak I found - and this is the one I am yet to forgive GM for putting me through – I discovered after I thought my work on roof rail screws was enough and I still had a leak that appeared to be coming from the rail screw openings – the rear right one in my case. So, I took the rails off, used masking tape to cover the screw holes, had the rear half of the headliner hanging down, and waited for the rain – this was during a rainy season in Detroit, I only waited less than 24 hours for Mother Nature. I laid down in my truck in the rain with the headliner pulled down and gazed in awe and endless amusement as the drips came down roughly 10 seconds apart from the dimple caused by an aggressive spot weld between the quarter panel and roof sheet metals. I have to admit I laid there for about 10 minutes staring at the drips, as I pondered the whole chain of events that led me to purchase a GM product to begin with. It’s one thing for gummy seal to wear around a sunroof rail or even for an engineer to sign off on open ended screw holes on the roof, but how do you screw up a spot welds? How many years now have the auto industry been spot welding? So long story short, I used more silicone on the bad weld spot in the trough area under the roof rail. You can see what I mean in the two graphics attached.

Oh and I had another leak from around the third brake light – chimzel? Is that what they are called? So I have silicone around and in the top gap between the light and plastic trim piece it goes in.

All in all, I used about 5 oz. worth of silicone on this truck to cover up leak paths. But hey, not a drip for more than a year now, so at least this story had a happy ending.
 

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2004 buick rainier
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gee maybe you could get a job as a gm leak tester!! LOL!! but seriously great job on the leak detection, been raining here for 2 days now and pretty heavy and so far no leaks fingers crossed!!!:thumbsup:
 

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2004 buick rainier
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well did the roof rack thing too found evidence of water under the rails so cleaned it up siliconed all the fasteners in the roof and applied new tread sealant to the bolts here's to hoping!!!:crazy:
 
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