VW California T5 ONLY Roof Corrosion - General Discussion

[KGCali]

I’ve got a sensor in the post, I’ve read that the T5 suffers from abs sensor harness issues where a crimped joint corrodes at the point where the abs cable joins the loom although I’m getting 11.4v at the sensor and 660ohms resistance across the sensor (both sides), was hoping to find a clear issue, going to try swapping the sensor before looking further.

Hope the sensor fixes it, if not this video could be useful ...

 

[Colne-camping]

I have a 2006 California, and the seal on the roof cowl is now split and becoming loose.

I guessing because it's separated it could be a plastic cap.

Can anyone recommend someone near Pendle Lancashire to get it looked at and repaired.
I've just had to tape it up for the time being to try and stop water flooding in.

Thanks

 

[Paul_W]

I have a 2006 California, and the seal on the roof cowl is now split and becoming loose.

I guessing because it's separated it could be a plastic cap.

Can anyone recommend someone near Pendle Lancashire to get it looked at and repaired.
I've just had to tape it up for the time being to try and stop water flooding in.

Thanks
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Definitely looks like it had the VW roof repair where they cut away the front section of the roof and bonded a plastic cap on top, we had the same issue, the bonding failed and the cap separated letting in water. We had ours removed and rebonded by VW under warranty as it was their warranty repair that had failed. It was fine after this second repair. I’d check in the first instance when the original roof repair was carried out by VW then you can establish if they should be fixing it under warranty. All records of repairs and dates should be on the VW dealer systems so any van centre should be able to check for you.

 

[COAST22]

Claridges of Southport did a good job on my warranty work re T5.1 roof corrosion. Maybe worth trying to find out who did the work on your van?

 

[KGCali]

I have a 2006 California, and the seal on the roof cowl is now split and becoming loose.

I guessing because it's separated it could be a plastic cap.

Can anyone recommend someone near Pendle Lancashire to get it looked at and repaired.
I've just had to tape it up for the time being to try and stop water flooding in.

Thanks
View attachment 116294View attachment 116295

Claridges did a great job on my cowl under warranty after the first cowl repair leaked. There should be a three year warranty with whoever did the original repair so worth investigating as the whole cowl will have to come off and a new one fitted if VW do the repair. If out of warranty then may be worth trying to get quotes from a few local caravan or boat repair centres.

 

[Colne-camping]

Thanks for the recommendations, but unfortunately Claridges of Southport no longer deal with California's, because they take up too much room in the workshop, and too much bother to deal with. Says alot about the van ‍

 

[KGCali]

@Colne-camping here is a list of VW Approved Repairers for the California Roof issues that VW gave me when I had corrosion on the elevating roof a few years ago, I used Lookers at North Shield and they did a great job, complete roof off and respray. Hope this helps.

 

[Perfectos]

Thanks for the recommendations, but unfortunately Claridges of Southport no longer deal with California's, because they take up too much room in the workshop, and too much bother to deal with. Says alot about the van ‍

It tells you something when the repairer chooses not to deal with VW design issues!
Once the repair was allocated to the repairer VW literally washed their hands of the whole issue , leaving customers to deal with the Repairer.
The repairer carried the can for the repair and any issues with it from then on !
It’s hardly surprising that the “repairer“ doesn’t want to play anymore

 

[slapping tim]

Roof Corrosion Warranty Fix Longevity
I can't believe this thread is still going, but I'm pleased it is, because I've something to report on this subject and might need some help. We had the Roof Corrosion Warranty Fix done on our 2011 California in 2017, which all looked good when it came back. A few years later we noticed a whistling sound at the top of the windscreen both sides when driving at speed. It looked like the plastic awning rail gutter piece extensions were coming loose. These must have been removed and replaced as part of the fix. This got progressively worse until these things were so loose that I could easily pull them off. What I found underneath was worrying. The plastic panel added as part of the fix had lifted at both sides and the bonding glue used for that and the plastic pieces seems to have lifted the paint off the metal allowing rust to develop underneath this. This now looked like a more expensive problem to fix than just sticking some plastic detailing back down on the bodywork. I took the van back into the dealer but they say that its now out of warranty, although this all started happening progressively within the 6 years and indeed I reported it to them to get the thing booked in within that time. Now rumour has it that the early fix procedure was prone to this problem and has since been changed. Is that true? I quickly trawled this chain and couldn't find anything on that instantly. If it is I would have thought that VW are liable to fix this regardless. Has anyone else had the same problem and if so what's the route to resolution?
Cheers,
Tim.

 

[Perfectos]

Roof Corrosion Warranty Fix Longevity
I can't believe this thread is still going, but I'm pleased it is, because I've something to report on this subject and might need some help. We had the Roof Corrosion Warranty Fix done on our 2011 California in 2017, which all looked good when it came back. A few years later we noticed a whistling sound at the top of the windscreen both sides when driving at speed. It looked like the plastic awning rail gutter piece extensions were coming loose. These must have been removed and replaced as part of the fix. This got progressively worse until these things were so loose that I could easily pull them off. What I found underneath was worrying. The plastic panel added as part of the fix had lifted at both sides and the bonding glue used for that and the plastic pieces seems to have lifted the paint off the metal allowing rust to develop underneath this. This now looked like a more expensive problem to fix than just sticking some plastic detailing back down on the bodywork. I took the van back into the dealer but they say that its now out of warranty, although this all started happening progressively within the 6 years and indeed I reported it to them to get the thing booked in within that time. Now rumour has it that the early fix procedure was prone to this problem and has since been changed. Is that true? I quickly trawled this chain and couldn't find anything on that instantly. If it is I would have thought that VW are liable to fix this regardless. Has anyone else had the same problem and if so what's the route to resolution?
Cheers,
Tim.
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It looks like the primer / base coat was applied, then the plastic trims refitted and masked up before the Clear coat was applied (which seals the panel against weather).
This simply would not make sense in a competent repair situation,
but it does look like that from the photos.

The remedial work to correct that is not as bad as the photos make it look. A good body shop will be able to sort that out easily, apply a Zinc high build primer and blend in the New paint to the A Pillar (full length of A-pillar), you wouldn’t be able to see the repair if done properly.

unfortuntely the problem will probably repeat on the other side ?

If it were me I would have a body shop properly prep and respray the entire cap and both A Pillars , if done correctly you will not see any colour variation because the new paint will extend to a natural break at the bottom of the A Pillar And the cap has a natural joint that is not normally visible With the roof down.
Top that off with new clear plastic anti wear pieces and it would look like new.

 

[Perfectos]

See Mark up

the Red is where the masking witness shows , the yellow is probably the extent of the original repair.
you can clearly see the is no clear coat (Lacquer) from the witness mark right up-to the cap.
It does not make sense but it does look like that is how the repair was done , therefore the plastic trim allows water to be retained against the colour / base coat (which is porous & water based ! ) allowing the rust to develop where the original paint had been rubbed back to effect the cap repair works. (Yellow line )

Edit. A good body shop should be able to talk you through the correct remedial measures and take photos before during and after the works so you have a full record of the repair and how it was done.

here is an example of what I would be looking for in the way of a photographic record (obviously this is only an example)

 

[slapping tim]

See Mark up

the Red is where the masking witness shows , the yellow is probably the extent of the original repair.
you can clearly see the is no clear coat (Lacquer) from the witness mark right up-to the cap.
It does not make sense but it does look like that is how the repair was done , therefore the plastic trim allows water to be retained against the colour / base coat (which is porous & water based ! ) allowing the rust to develop where the original paint had been rubbed back to effect the cap repair works. (Yellow line )

Edit. A good body shop should be able to talk you through tge correct remedial measures and take photos before during and after the works so you have a full record of the repair and how it was done.

here is an example of what I would be looking for in the way of a photographic record (obviously this is only an example)

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Hey this is great, thanks for taking the time to respond so comprehensively. One further question though. What about where the new plastic panel has lifted at the ends? Can that just be 'sealed' or does it need taking off completely and re-fitting which I assume would mean a new one?

 

[Perfectos]

Hey this is great, thanks for taking the time to respond so comprehensively. One further question though. What about where the new plastic panel has lifted at the ends? Can that just be 'sealed' or does it need taking off completely and re-fitting which I assume would mean a new one?

The plastic panel is decorative, the body shop would advise , but I would have thought they would leave thd cap in place , do all the prep work and re seal the existing after a proper repair

 

[Colne-camping]

So north shields no longer deal with the roof issues, as the technician that did the work no longer works there ‍

I too have whistling and considering renting a unit, all the tools, and doing it myself, as it seems it's going to be the easiest and quickest way to find someone to deal with it

 

[BoredArtist]

T-5 Years and years out of warranty> Needs famous paint blister work repair.
Anywhere around Guildford ...Anyone know?

 

[KGCali]

T-5 Years and years out of warranty> Needs famous paint blister work repair.
Anywhere around Guildford ...Anyone know?

My 2010 T5.1 Cali got the roof edge corrosion done under warranty a couple of years ago so always worth asking VW You could be waiting a couple of years for the VW repair though
If not then look for a classic car or boat restorer that's use to working with aluminium. Good luck!

 

[Ch1pbutty]

Our 2012 got put on the waiting list about 5 years ago when it went in for its first service under our ownership at SMG Cowfold.. “a recall has come up for the roof, van will be collected on low loader and taken to a specialist bodyshop for repair, courtesy van will be supplied while the work is done & then the van will be dropped back you”. Have heard nothing further since . Chased them whilst it was in for service this week, can’t see them ever actually doing anything.

 

[makisparrow]

I know I'm late to the party but I would really appreciate your expert opinions on this. Just recently bought my first T5 and noticed water coming in while washing with pressure washer.

I see no corrosion on neither side of the roof cap, but there's a gap on the elevating side. Both drain holes are working.

My questions are: has it had the tape applied? What should I do to eliminate the leaking?

Thanks a lot for the help!

 

[Lambeth Cali]

I know I'm late to the party but I would really appreciate your expert opinions on this. Just recently bought my first T5 and noticed water coming in while washing with pressure washer.

I see no corrosion on neither side of the roof cap, but there's a gap on the elevating side. Both drain holes are working.
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My questions are: has it had the tape applied? What should I do to eliminate the leaking?

Thanks a lot for the help!

I might be wrong but that looks like a plastic cap has been put over the top. This was one of the attempted fixes I think. Could be wrong.

My 2008 T5 doesn’t particularly leak but I am now a little careful around certain bits with a pressure washer. Would avoid cap altogether.

Where was the water coming in?

 

[Pyabies]

I know I'm late to the party but I would really appreciate your expert opinions on this. Just recently bought my first T5 and noticed water coming in while washing with pressure washer.

I see no corrosion on neither side of the roof cap, but there's a gap on the elevating side. Both drain holes are working.
View attachment 120913View attachment 120914View attachment 120915View attachment 120911View attachment 120912
My questions are: has it had the tape applied? What should I do to eliminate the leaking?

Thanks a lot for the help!

Not sure if helpful but the pipe that drains these holes runs through the front pillars either side of the windscreen, depending where any ingress happens will show if this this tube and its connection is at fault.

 

[KGCali]

I agree with @Lambeth Cali that it looks like the cowl has been repaired in the past and the sealant has perished around the cowl. If the previous owner has proof of the previous repair and it was within the last two years then it may be covered under warranty. If not then I'd take to to a caravan repair shop and get it resealed all around the cowl with Sikaflex 221 or a similar sealant.
I noticed you have a small area of rust at the top of the windscreen, this is another common area for water ingress so worth getting it repaired at the same time.
It's good to keep the cowl to roof junction clean to prevent blocking the drain holes so worth regularly gently washing regularly by hand and conditioning the roof seal with silicone spray or similar, definitely do not use a power washer around the cowl!

 

[makisparrow]

Thanks a lot for your answers.

Attached is a photo to show where it got wet.
I've checked both drain wholes and no problem there (water runs down on the tyre).

Not sure what the plastic cap is that you refer to, but I assume it's protection for the galvanic corrosion. Good to know it's not a structural hazard either way.

I will see what info I can find from VW about the repair and if not I will probably just chuck some Sikaflex myself to seal things off.

Great support, appreciate it!

 

[AlistairC]

Agreed with the comments above.

The VW method of fixing the cowl corrosion was to simply cut corroded parts of the cowl out and to glue a plastic capping on top and paint to look pretty.

Many of these repairs seem to have failed subsequently due to expansion causing the plastic to crack or failed sealant. Yours looks to me like failed sealant - water gets between the remnants of the old cowl and the plastic capping and into the roof area. That said, I’d expect the water to come through somewhere in the middle of the roof lining and not by the grab handles - grab handle area leaks are more likely to be roof drain components leaking. Perhaps you have both?!

Best suggestion, don’t pressure wash it and get busy with the sika!

 

[Paul_W]

Thanks a lot for your answers.

Attached is a photo to show where it got wet.
I've checked both drain wholes and no problem there (water runs down on the tyre).

Not sure what the plastic cap is that you refer to, but I assume it's protection for the galvanic corrosion. Good to know it's not a structural hazard either way.

I will see what info I can find from VW about the repair and if not I will probably just chuck some Sikaflex myself to seal things off.

Great support, appreciate it!

View attachment 120922

Your Cali has definitely had the corrosion repair, the whole front section of the roof is basically a plastic cap they bonded over the original roof section to cover up where they cut away the corroded section. We had the exact same issue, the bonding fails over time and you get water ingress, ours leaked in the same place as yours. I did try sealing around the edges of the cap myself but without success. Fortunately we were still in the warranty period for the roof repair so it went back to VW. They removed the plastic cowl cleaned everything up and re bonded it. They use a different bonding material now and we had no issues following the second repair. So definitely first port of call is VW to see if they will rectify their failed repair. The problem with trying to reseal it yourself is getting even pressure on the cowl to hold it firmly in place while the sealant sets if you don’t the cowl will just keep lifting and break the seal again. Good luck with getting this sorted.

 

[briwy]

Agreed with the comments above.

The VW method of fixing the cowl corrosion was to simply cut corroded parts of the cowl out and to glue a plastic capping on top and paint to look pretty.

Many of these repairs seem to have failed subsequently due to expansion causing the plastic to crack or failed sealant. Yours looks to me like failed sealant - water gets between the remnants of the old cowl and the plastic capping and into the roof area. That said, I’d expect the water to come through somewhere in the middle of the roof lining and not by the grab handles - grab handle area leaks are more likely to be roof drain components leaking. Perhaps you have both?!

Best suggestion, don’t pressure wash it and get busy with the sika!

I reseal ours every year. Needs to be very clean and dry. I rub it over with alcohol before applying the sealant. Whatever sealant you use it will eventually fail so needs keeping an eye on it.
Ours went back three times to try to cure leaks after the modification and still didn't sort it. Complete shambles.