Hey everyone,

The previous owner installed a Kenwood amp (I believe it is) and also installed a tspec cable wire...but the wiring goes through this gasket (seen in pictures under the hood)

Now, issue is that when it rains heavily it leaks through this gasket and into the foot well.

At first I thought the AC ducts were clogged and I cleaned them, and then I checked the windshield seals but those were also good and upon running water over the cross member of the side panels I've found the issue which is the water is somehow getting to this gasket and running inside.

Luckily the foot well has no rust and everything looks good.

However, how can I prevent this from leaking anymore and would any of you recommend me fixing the rust underneath the gasket?


Inside under dash

Inside under dash

Under the hood (KC wiring is red and black wire)

Under the hood (KC wiring is red and black wire)

Under the dash inside (tried my best to get the picture)

Rust spot

Inside tire well where the rust spot is building

 

a little clear silicone sealer around the gasket will do the trick - Permatex is really good one

 

I guess it depends how long you want to keep the vehicle. It is already around 30 years old.

I have had good luck using Loctite Rust Restorer for treating rusted steel (needs to be sandpapered or wire brushed first). Both the '94 and '96 had a lot of rust there at the front wheel wells, especially at the mud flap bracket areas that caused holes in the floor boards. I drilled drain holes right at the bottom of the valley (your engine bay photo with two holes showing lower right) as water can puddle up there. Removed the plastic wheel well liner and drilled just even with the bottom edge so the liner covers the drain hole (5/16 or 3/8 inch). Then I patched the holes shown in your photo with seam sealer (it's a bit tougher than silicon caulk and can be painted over). Definitely wire brush that rusty section of the wheel well right behind the tire, then use a good quality (e.g. 3M) rubberized paint to coat the wheel well (maybe seam seal the joints first). One can of paint will cover both sides if the original coating is not too bad, otherwise one can per wheel well.

If your truck is like mine, there were rust holes hiding up at the top of the plastic wheel well liners. After using Rust Restorer, I patched those holes with sheet metal, fixed in place with seam sealer, then rubberized paint. I figure it will be good for another 20 years or so. What year is your truck?

I also recently placed silicon sealant at the upper corners of the windshield to prevent water infiltrating behind the rubber finishers. A lot of water goes there from the roof channels, etc. I suspect water from there ended up soaking the carpet and rusting out my floor boards. A little black or clear silicon to fill the gaps between and under the rubber pieces is almost invisible unless you look closely. Hope this is helpful.

 

I recommend POR-15 to stop the rust - no prep needed