Originally posted by BLACK XR6-VCT
I have located the problem with the help of Ford dealership:
The brake booster box is welded to the underneath of the scuttle panel. Because the box comes under some pressure, this can cause hairline cracks in the scuttle panel, where water will leak through. This can be welded by ford (they have to remove dash) all up $500. I will attempt to fix this myself with silicone - probably not a permanent solution, but cheaper, if the problem comes back I will have to weld.
Mate, if you have to pull anything to bits to fix this, you're much better off to do it right the first time. If you bodge it up with silicone, I believe you're asking for trouble..
If you really need to seal it up temporarily, use a good quality sealant such as sikaflex. It's very flexible, and dries so you can paint it. Plus it will not promote rust like silicone will..
The best way is to effect proper welding repairs, and maybe strengthen the weak compnents so they don't crack again!!!
Shame on Ford for STILL not fixing a peculiar Falcon water leak problem that has been with us forever.....