FTO AUSTRALIA

First issue is, I have quite a water leak on the passenger side.
At first I thought perhaps it was from when the heater core was replaced. Are there supposed to be rubber seals in there?-

After having a look though, I'm not so sure that even if there are supposed to be seals, if that is the issue here. Have discovered that the water is leaking in through here, just under the glovebox:

I don't really understand why or how.... it obviously shouldn't be able to drip down from there as there is only foam between the plastic....any help? it seemed to be happening when the air con was on, although it wasn't leaking a great deal, but we have had quite a bit of rain over the last few days and the passenger side is soaked....so it's not just from the air con, it's a leak from the outside.


Whilst looking around and checking my oil levels and whatnot I found something else interesting. If I wobble the brake fluid container, the whole bracket rocks on the seal.... Would it just be as simple as a done seal?



On another note, when I first purchased the car I found I had to occasionally double clutch to get it into reverse, something I wasn't particularly worried about as I had been having to do so in my Barina. However, now it sometimes decides it doesn't want to get into reverse at all, though it tends to go in if I first put it into first gear and then try back in reverse. Is this a normal issue or is my gearbox going?
I also find that when driving, if I start slowing down and the gear is in too high, instead of just grumbling and struggling a bit, it will make grinding sounds until I get it into a lower gear. Obviously this isn't something I do regularly or on purpose, I only realised it happened when I was slowly pulling into my drive way and for some reason it decided second gear was too high...


Also, the suspension is quite stiff, which I don't have an issue with, however, when accelerating around corners or while going over bumps, the steering seems to get thrown a bit. Is this normal or should I be checking my shockers?


Any knowledge that you can pass on would be greatly appreciated.

The other thing is, today when going to start my car, it wasn't clicking over, so I pumped the accelerator a bit, and it still wouldn't click over.
It wasn't until I stopped turning the key and let it fall back into place that the car started...
It was really strange
And it has started fine since then

Try and cover these in the order raised:

First issue is, I have quite a water leak on the passenger side.
At first I thought perhaps it was from when the heater core was replaced. Are there supposed to be rubber seals in there?-

As its got a brand new heater core, it wont be that unless the hose clamps are a little loose (worth a check). Did just have a thought though. There are normally foam seals between the pipe and the inside firewall, but they pretty much disintigrate when you take the core out. Never thought they served much of a role, so didnt worry too much about them. If water runs down that hose though, thinking about it, it will potentially run into the car. With this in mind, it might be worth filling somehow. As you arent loosing any water out of the system (the overflow tank is not dropping then it will be an outside water issue like that ive described above.

Whilst looking around and checking my oil levels and whatnot I found something else interesting. If I wobble the brake fluid container, the whole bracket rocks on the seal.... Would it just be as simple as a done seal?

The master cyllinder container does rock on that seal between it and the metal. Unless its leaking, that is normal (I just checked on the car outside and it rocks too). SO unless its leaking, dont worry about it. I have spares if you do need one.

On another note, when I first purchased the car I found I had to occasionally double clutch to get it into reverse, something I wasn't particularly worried about as I had been having to do so in my Barina. However, now it sometimes decides it doesn't want to get into reverse at all, though it tends to go in if I first put it into first gear and then try back in reverse. Is this a normal issue or is my gearbox going?
I also find that when driving, if I start slowing down and the gear is in too high, instead of just grumbling and struggling a bit, it will make grinding sounds until I get it into a lower gear. Obviously this isn't something I do regularly or on purpose, I only realised it happened when I was slowly pulling into my drive way and for some reason it decided second gear was too high...

I just asked the wife about reverse and she said she had to occasionally double clutch to get into reverse and on the odd occasion that I drove it, I have occasionally needed to do this as well. I have found with respect to the grinding, the only time it had done it to me is if I didnt have the clutch quite far enough in. Worst case scenario, it will be the clutch or the slave cylinder. If this ends up being an issue, I have a clutch on the shelf in the shed you can have. If its the slave cylinder, you can get a seal kit for them that wont set you back too much.

Also, the suspension is quite stiff, which I don't have an issue with, however, when accelerating around corners or while going over bumps, the steering seems to get thrown a bit. Is this normal or should I be checking my shockers?

The suspension on the car is fairly stiff out of the factory. The stiff suspension wont cause this (and has brand new shocks on the back). The car will tram track a bit (follow the grooves in the road) if the wheel alignment is out though. As ive had to have the wheel alignment on the Legnum done about every 10000km due to the ruts on our dirt road and given the fact that the tires are getting on a bit now on the car, I wouldnt be surprised to find it was due for an alignment. Id have this checked first. Toe in or Toe out in the alignment will cause the car to have a bit of a mind of its own, especially if accellerating reasonably quickly or driving on a road that is not smooth.

Hope this helps

That was my first thought. I remembered where you had said the hoses connect to and where the core is located when showing us the ute FTO, so the first thing I looked at was the hoses and realised that it appeared to be lacking some kind of seals. Will definitely be having a better look and testing it out and will keep you posted.

It's good to know that the issues with both the master cylinder and suspension aren't worth worrying about lol. I figured the steering issue would most definitely at least partially have to do with needing a wheel alignment, just thought it would be a good idea to cover all possibilities just incase the alignment didn't quite fix it. As you well know, I will be getting tyres very shortly, am calling in tomorrow to book it in so all should be good in that regard once that has been done and they have been aligned properly.

The clutch is quite a worry, but like I said on the phone, I am booked in for a service in a few weeks, so I'll get my mechanic to specifically check that for me. Should be fine til then.

Just wish I knew a bit more myself so I could diagnose and fix the issues here and now lol, was originally going to be a mechanic......so I find it quite frustrating when I'm just not quite sure about something. Your insight has definitely made me feel much better. And as I said, will keep you posted.

Well, if you end up needing a clutch, let me know and ill send you the one on the shelf I have.

klyfe wrote: I also find that when driving, if I start slowing down and the gear is in too high, instead of just grumbling and struggling a bit, it will make grinding sounds until I get it into a lower gear.

I've always had that noise I think... night quite a grinding but but more like shaking screws in a can... well sort of.
Apparently it's normal?

i want to see this fto ute dstocks been looking at pics trying to work out if it was me how i would do it just interested to see how you went about it if i had a spare fto ild love to try make one to ( of course you would have to hurry and finish yours so i dont steal your thunder )

The ute looks amazing. I couldnt picture it either. But surprisingly it suits quite well

Argggg, missing bits at the moment, so isnt going anywhere. It needs bits to get it going again (including an engine). Have been robbing the odd thing off it lately that im going to have to replace.

On the bulkhead under where the heater pipes run into the car is a small black rubber outlet pipe. It lets the water that your air con condenser draws from the air escape. I would guess that this is blocked and it is not escaping. Try giving it a squeeze as it can stick to itself and seal up.

Some how, I don't think that the air con could saturate the passenger side overnight whilst the car is off....
The water found it's way through the firewall during massive rainfall. Nothing to do with the a/c.
Haven't had a chance to sort anything out about figuring out the leak as of yet, have been overwhelmed with other things to deal with, but my partner is working away this weekend so it gives me the perfect opportunity to spend some time with my car.
Will keep you posted on what I discover.

Im thinking it still must be going through where the heater pipes enter the firewall.

I still thats still a lot of water to get past the bonnet seal then find its way to the specific part of the bulkhead where the pipes come through, then find its way into the heater air intake ducting dstocks.

After more consideration though, even if it was the air con evaporator drawing in more wet air due to the rainy conditions, dehumidifying it and then the water not draining away, you would probably have misting up of the windows and you haven't mentioned this...

An interesting one I think!

Actually storm is possibly onto something there. I didnt know that drain outlet was there. Make sure the little black pipe is actually sticking out of the hole it is supposed to be sticking out of still (below heater pipes). When I put the heater core in, I had to move things a little to get it in and its technically possible that that pipe has escaped back into the cabin and is not venting out of the car anymore, but inside the cabin. Worth a check.

Sorry it took so long to get back to you about this, had a lot going on.
Storm seems to have actually been correct.
I'm still not sure how the water was managing to get in from the rain, but the a/c hose was indeed stuck to itself, and once I squeezed it and let it drain, it hasn't leaked into the cabin again.
The end of the a/c hose is actually split, and continues to want to flatten at the end, so I've got to chop it, but like I said, it seems to have solved the issue.
I'm still not sure how the rain was managing to get in over night though.

klyfe wrote:Sorry it took so long to get back to you about this, had a lot going on.
Storm seems to have actually been correct.
I'm still not sure how the water was managing to get in from the rain, but the a/c hose was indeed stuck to itself, and once I squeezed it and let it drain, it hasn't leaked into the cabin again.
The end of the a/c hose is actually split, and continues to want to flatten at the end, so I've got to chop it, but like I said, it seems to have solved the issue.
I'm still not sure how the rain was managing to get in over night though.

Woo-Hoo Go Me!!!!!!

Dont know why the end of that hose is folded at the end in the way it is but that does cause it to stick to itself sometimes.

Problems and little issues like these never cease to amaze me...

As for the water in the cabin, i'm sure it is possible your A/C condensate tube as you say will close and fill up, to make it's way into your cabin once you have stopped driving having your A/C on there will still be condensate draining. If this is the case turn the A/C off a good time before you park and lock up your car? Just a thought Also nice hot/warm sunny day leave your car to air out and have a hit and miss once she is high and dry!

I can't say i have had A/C problems as of yet but i have dealt with A/C problems in a previous life (my other cars)

Cheers Damo.

Your still not getting my point
Yes, the water was getting in the car as the a/c hose was blocked, so it was backing up into the cabin.
But the water wasn't there because of the a/c.....
Both of the days before the rain, I drove my car for like, 20 minutes max, and I didn't have the a/c on.
Then it rained heavily for a good 24 hours, and when I hopped back in, the passenger side was absolutely drenched.
Somehow the rain was getting through the firewall, and was then trying to drain out the a/c pipe....

I believe that is where the foam bits could come in. The foam circles that fitted between the heater core and the firewall on the inside of the car were perished beyond recognition and I didnt put them back in as they would not have stayed there anyway. I didnt get any with the new heater core and thought they were for soundproofing or something and didnt think too much more of it. I think the water may be running down the firewall and landing on top of the heater pipe and then following it through the firewall into the footwell. I would use some expanding foam maybe to seal this off (maybe someone else could suggest something better).

I indeed am still going to seal that up, as a precaution if nothing else.
It rained again today and a bit of water managed to get it, so I'm definitely sealing around those hoses, and I need to chop the end of the a/c hose as it is cracked and continues to stick to itself.
Basically, I know how to fix the issue, as I have found out that the water needs to escape from the a/c hose, whether the water is coming from the a/c itself, or if it's managing to get in with the rain, and it is an easy fix.
Just want people to acknowledge that it's not a simple a/c issue.......I'm smart enough to work out something as simple as an a/c block
It's the rain that's causing it.
Will be sealing up the gap around the heater core hoses on Monday, so I guess that next time it rains (which with this weather, probably won't be too far away) I will let you know how it holds up.