NHTSA Complaint #11322212 — 2016 FORD FIESTA

MY VEHICLE IS A 2016 FORD FIESTA ST WITH A SUNROOF. I LIVE IN AN AREA WHERE THERE IS NOT MUCH FLAT LAND TO PARK VEHICLES. MY DRIVEWAY IS GREATER THAN A 20% GRADE. THIS COMPLAINT IS RELATED TO SUNROOF SEAL LEAKS IN ANY MODE OF OPERATION. THE SUNROOF SEAL IS A SINGLE STRIP OF RUBBER WITH A DISCONNECTED SEAM THAT IS ORIENTED AT THE TOP OF THE SUNROOF. AS THE RUBBER AGES, THE RUBBER SHRINKS AND THE SEAM CAN DEVELOP INTO A GAP THAT LETS WATER INSIDE THE SUNROOF DRAINAGE TRAY. IF THE SUNROOF SEAL LEAKS OR FAILS, THE CAR IS DESIGNED TO COLLECT THE WATER AND DRAIN IT TO A LOCATION NEAR THE FRONT WHEEL WELLS. THIS WORKS PERFECTLY AS LONG AS THE CAR IS LEVEL. IF THE CAR IS PARKED AT A 15% GRADE OR STEEPER WITH THE FRONT OF THE VEHICLE POINTING UPWARDS, THE SUNROOF SEAL WILL LEAK, BUT THE WATER COLLECTED WILL NOT DRAIN TOWARD THE INTENDED DRAINS. THE WATER WILL INSTEAD FLOW DOWN THE SIDES OF THE ROOFLINE INSIDE PLASTIC TROUGHS. THESE TROUGHS ARE NOT WELL DRAINED TO THE EXTERIOR. THE WATER WILL FLOW THROUGH THE TROUGHS AND EXIT INTO THE INTERIOR OF THE VEHICLE NEAR THE HEAD LINER AND THE REAR PLASTIC TRIM OF THE INTERIOR NEXT TO THE REAR WINDOW. THIS WILL EVENTUALLY FILL UP THE SEALED SPARE TIRE WELL, AND WILL CAUSE CORROSION OVER TIME. THIS CORROSION MAY AFFECT THE CAR'S STRUCTURAL INTEGRITY AND MAY AFFECT THE CAR'S CRASH WORTHINESS IF ALLOWED TO CONTINUE. THE WATER IS ONLY NOTICEABLE IF THE TRUNK SHELF IS REMOVED, WHICH IN MANY VEHICLES WILL NEVER HAPPEN. THE WATER ALSO HAS A TENDENCY TO COLLECT ON THE REAR SEATBELT SPOOL AND THE SPOOL SUPPORT FASTENERS. IF THE WATER IS LEFT ON THE SEATBELT SPOOLS FOR LONG ENOUGH TIME, THE SEATBELTS FOR THE REAR SEATS CAN BE WEAKENED OVER TIME BY CORROSION. THE SEATBELT ISSUE MAY NOT BECOME A SAFETY CONCERN UNTIL SOMETIME IN THE CAR'S FUTURE IN THE SECONDHAND MARKET. BLACK MOLD GROWTH MAY BECOME AN ISSUE AS WELL.