The silicone that was used to patch up the hole in the front windshield and top of A-pillar rain gutter area (a number of years ago) needed to be re-done. I am going to use JB Marine Epoxy Weld to plug it up for a better seal against the weather elements.

I cleaned up the area. However, I do not remember seeing there was such a large gap (see circled in pic). It is the same sized gap on both driver and passenger sides.

Just doing a sanity check.... is the gap generally this large? Or I am wondering if perhaps there is some sealing piece that went missing when the front windshield was replaced a few years ago by the glass shop?

 

@acg Went out and looked at mine looks like the sealant just gave up and broke away - I would have the same sized hole if I dug it out on mine.

Still need to get out and grab that awning too.

 

Checked on my 03 and there's a finger sized hole on both sides on that spot.

 

Water is supposed to exit the gutter and go through that hole and then out the bottom. Why do you want to plug that?

 

@Brandon318 actually is supposed exit the gutter and run down the edge of the windshield, that hole should be covered

 

Ah yeees yeees, you’re right. Just took a look at the discos and see that. Not sure why I thought the other way around.

 

Geesh, I had finger sized holes in mine too, thanks for pointing that out so I'd go look! Sealed mine up with leftover windshield sealant from my sunroof repair job.

 

Thanks to everyone for re-affirming my sanity!

Richard G: I will see if I can swing by your place this weekend. Talk soon!

 

This is how my 03 looks like on that spot.


Doesn't look so big on the photo.
Made a quick fix/test and put some tough and wide gorilla tape on the hole to direct the water on the glass.
Going to get a heated screen before winter as some of the previous owners have been cheap and replaced a heated with non heated screen.

Have had some water coming in for some time now apparently. Luckily the Fordium(rust) is only on the surface except the grommet on the firewall that has started growing downwards.
http://i.imgur.com/bgcGgZI.jpg

 

I am pretty sure there was a technical service bulleting about this. If I recall, the TSB referenced improper/incomplete welds in this area. I put black silicone in the open spaces on mine. Seemed to stop water intrusion,