Front roof panel loose ☹️

[Paul_W]

Hi all,

We have come across an issue with our recently purchased Cali. While driving on the motorway the other weekend noticed an increase in wind noise on the passenger side up near the top of the window. On closer inspection I found the front roof panel was loose on the passenger side. So you can actually just with your finger pull the front panel up a good inch! So it’s fine on the drivers side seems to be loose from about half way across the roof. It had the vw warranty roof repair done sometime last year, over a year ago now so I assume when they refitted the front panel they didn’t attach it properly I did try and seal it with some clear mastic stuff that worked for about a week then came loose again. My concern is not so much the wind noise though it is annoying but more that if air can get in maybe water can get in as well? So currently it has insulation tape all round the loose part which looks messy but keeps the rain out and stops the wind noise.

I don’t know how that panel is supposed to be attached and what would be involved to reattach it

I’ve been in touch with vw customer service and quoted the original roof repair reference and asked them what help they can offer. They just said take in into a vw commercial dealership to get it inspected.

I wondered if anyone else has had similar issues or could offer any advice that might be helpful. I’d like to be prepared before I start into any negotiations with vw.

Thanks, P.

 

[Hotel California]

There has been reports of thesame in the thread on the roof corrosion.
If it's only been repaired a few months under VW warrenty should have a warrenty on the repair itself...

 

[WelshGas]

Hi all,

We have come across an issue with our recently purchased Cali. While driving on the motorway the other weekend noticed an increase in wind noise on the passenger side up near the top of the window. On closer inspection I found the front roof panel was loose on the passenger side. So you can actually just with your finger pull the front panel up a good inch! So it’s fine on the drivers side seems to be loose from about half way across the roof. It had the vw warranty roof repair done sometime last year, over a year ago now so I assume when they refitted the front panel they didn’t attach it properly I did try and seal it with some clear mastic stuff that worked for about a week then came loose again. My concern is not so much the wind noise though it is annoying but more that if air can get in maybe water can get in as well? So currently it has insulation tape all round the loose part which looks messy but keeps the rain out and stops the wind noise.

I don’t know how that panel is supposed to be attached and what would be involved to reattach it

I’ve been in touch with vw customer service and quoted the original roof repair reference and asked them what help they can offer. They just said take in into a vw commercial dealership to get it inspected.

I wondered if anyone else has had similar issues or could offer any advice that might be helpful. I’d like to be prepared before I start into any negotiations with vw.

Thanks, P.

The original repair was to replace the whole front roof Aluminium assembly at £4000+ so VW came up with a cheaper repair. Treat the Galvanic Corrosion and cover it with a colour coded plastic cap.
A couple of members who have had this repair have reported the same as you.

https://vwcaliforniaclub.com/threads/vw-california-t5-only-roof-corrosion-general-discussion.9000/

 

[Paul_W]

There has been reports of thesame in the thread on the roof corrosion.
If it's only been repaired a few months under VW warrenty should have a warrenty on the repair itself...

Ok I’ll have a look in there. Unfortunately it was repaired over a year ago and I’m not sure how long the warranty on the repair is, from what I’m reading seems the warranty on the repair is only 12 months. Which seems poor

Thanks for the reply.

 

[jts46]

It still could be within the extended warranty that VW gave for this problem. What was the original purchase date?
VW extended the warranty for this problem to 6yrs

 

[soulstyledevon]

I had this is issue with my last vehicle. Cali Beach.
It went back three times and on its third return I put the vehicle up for sale. Had enough of the issues.
I would chase Volkswagen for this.
They usually offer 2yrs Warranty on parts replaced, can’t see why this wouldn’t fall under the same scope.

 

[WelshGas]

With this type of repair, if the Plastic Cap was a perfect fit it would take very little adhesive to hold it in place. So, it is either not a perfect fit or is getting deformed by the heat and so lifting off. Either way I don’t think we have heard the end of any problems with this cheaper repair. I hope I’m wrong.

 

[Paul_W]

Oh so this is just a plastic cap stuck over the original roof panel? Didn’t realise that... if that’s the case I guess my worries about water getting in are not justified then? Just be good to get it sorted as the wind noise is annoying and it looks rubbish at the moment with tape all over it

Thanks for the replies everyone

 

[Paul_W]

Oh and it’s a 2012 year. So was in extended 6 year warranty period when it was logged with VW originally for the issue.

 

[Meoncoast]

Oh so this is just a plastic cap stuck over the original roof panel? Didn’t realise that... if that’s the case I guess my worries about water getting in are not justified then? Just be good to get it sorted as the wind noise is annoying and it looks rubbish at the moment with tape all over it

My understanding that corroded area may have been cut out so I would be worried that there could be water ingress under the cap and having just driven through storm force winds in Scotland if the wind got under the non-stuck down side of the cap could the whole thing lift off. Ask VW if your cap flies off and hits someone are they going to accept corporate liability for their failed botched repair. I would say the repair is (in your case) not fit for purpose.

As VW have said take it to a dealer for inspection I would do that asap

 

[ArunAlec]

My understanding that corroded area may have been cut out so I would be worried that there could be water ingress under the cap and having just driven through storm force winds in Scotland if the wind got under the non-stuck down side of the cap could the whole thing lift off. Ask VW if your cap flies off and hits someone are they going to accept corporate liability for their failed botched repair. I would say the repair is (in your case) not fit for purpose.

As VW have said take it to a dealer for inspection I would do that asap

Agree, there are some photos on here somewhere showing the extent of the cutaway alloy beneath the cap. Definitely a potential for water ingress.

 

[Paul_W]

Ok thanks guys. It’s getting inspected by a VW camper specialist engineer that works for the same insurer as my wife on Wednesday. Once I’ve got his views I’ll be in touch with our local van centre for a chat with a view to getting it booked in.

 

[jts46]

Ok thanks guys. It’s getting inspected by a VW camper specialist engineer that works for the same insurer as my wife on Wednesday. Once I’ve got his views I’ll be in touch with our local van centre for a chat with a view to getting it booked in.

Any chance of a photo please, to see the problem?

 

[Paul_W]

I had this is issue with my last vehicle. Cali Beach.
It went back three times and on its third return I put the vehicle up for sale. Had enough of the issues.
I would chase Volkswagen for this.
They usually offer 2yrs Warranty on parts replaced, can’t see why this wouldn’t fall under the same scope.

Hi, How long after the initial repair did it come loose? Any argument with VW to get it rectified under warranty from the roof repair or did they just agree to it?

 

[Paul_W]

Any chance of a photo please, to see the problem?

I’ll try and get a couple tonight. There’s not to much to see with all the tape at the moment and it’s going to Halifax tomorrow so I don’t want to remove the tape at the moment. But you can see it seems to fit perfectly drivers side but comes up a bit short passenger side where it meets the gutter. You could see some sort of set black filler passenger side near the gutter but not drivers side. Will try and show that in the photos....

 

[Paul_W]

A few photos, can’t really see too much because of the tape. But need to leave that on as the Cali is off on the motorway to Halifax tomorrow. The first few show the drivers side which is secured fine but also clearly show from above that it’s a stuck on secondary panel. Above.

 

[Paul_W]

And here’s the passengers side.....

The back lifts up really easily a good inch the front not so much but does lift a little. The wind noise is very pronounced but that bit of tape along the front edge stops it all together....

 

[Rich20]

How can anyone be proud to have done a “repair” of such a poor standard. VW should be ashamed to say this is the best they can do.

 

[soulstyledevon]

Hi, How long after the initial repair did it come loose? Any argument with VW to get it rectified under warranty from the roof repair or did they just agree to it?

6-8 weeks.
That repair is not good enough, especially from VW

 

[Paul_W]

Quick update! The engineer my wife knows had a look at it this morning. He confirmed our suspicions that VW botched the repair, he said the amount of filler clearly visible on the passenger side of the roof panel clearly shows it was badly fitted in the first instance. He thinks because of the way it’s bonded it might need cutting out so it’s going to be a big job to fix

It’s booked in the VW Manchester van centre next Tuesday for inspection by the warranty guy. From there looks like they’ll liase with VWCV customer services about how to move forward. My concern is that it was repaired June last year so over 12 months ago and I’ve seen mentioned by some that the roof repair was only warranted for 12 months. Seems ludicrous that a major warranty repair like this for a known issue would only have a 12 month warranty. I just hope VW are sympathetic and agree to address under warranty

Will keep you updated......

 

[Meoncoast]

I just hope VW are sympathetic and agree to address under warranty

Personally cannot see how they could wiggle out of taking responsibility for the repair their agent cocked up.

 

[soulstyledevon]

Keep us updated.
I do hope they make this right.

 

[2into1]

When they add the cap, obviously that front spoiler part grows in every dimension. While that’s of little consequence at the front and the sides, it does mean the gap to the raising roof is reduced.
The rubber seal between the two parts of the roof is already tight, as can be witnessed when opening the roof after a period of inactivity.....it seems to initially stick then release with a pop.
Even with original gap, it must place a huge lifting force on the spoiler rear edge. That pressure must be even greater when that gap has been reduced by the addition of the cap, which of course is now just bonded rather than being a structural part of the roof which was better able to resist the upward force.
I’m wondering therefore the operation of the roof forces the rear of the spoiler cap to lift and break the sealant holding the cap in place?
If so, perhaps there is some tolerance in the rear hinges to slide the roof back a few mm (to reestablish the initial clearance) or if fitting a narrower front seal should be part of the repair process?

 

[MattBW]

I think the key words to use whenever dealing with VW on that is that the repair was clearly not fit for purpose in the first place, if its been fixed badly it's not going to last. Only reason it failed was poor workmanship.

 

[Paul_W]

I think the key words to use whenever dealing with VW on that is that the repair was clearly not fit for purpose in the first place, if its been fixed badly it's not going to last. Only reason it failed was poor workmanship.

I think you’re right

I have a copy of the original letter from VW to the club where they admit the issues and confirm the warranty extension from 3 to 6 years and confirm the repair would be warrantied for 3 years so I don’t see how they can argue with that.

We’ll see what happens next week once it’s inspected