The first picture is the new roof seam patch under the rack. Masked off the edges and dug out the old sealer, scuffed up the surface with steel wool and wrapped a layer of masking tape on the original bolt leaving a few threads exposed and threaded it in up to the tape, filled the opening and smoothed it flat then removed the bolt and the tape right away and let it self level(the bolt hole is covered because I skimmed it over with weather strip adhesive after a few hours). I would wait at least 4-5 days for the sealer to cure before reinstalling the rack using new foam pads from Ford or using foam tape or maybe RTV around the threads. There are 10 holes in the roof in total and 2 more for the front trim strips and usually but not always leak towards the side windows and down depending how its parked.
The second/third picture is the left side of the hatch hinge with it opened. ( The 3rd picture is the right side hinge
top left is the corner of the roof where it cracked (
#2 in third picture)
middle left is the rubber plug (#3 in the 3rd picture)
bottom left is the seam where it joins the hatch weather strip (#4 3rd picture)
top right is the crack on the inside of the hinge area (#1 3rd picture)
The last picture is the close up of the hinge area, the sealer just came up in chunks and over 90% of it wasn't even near the edge of the sheet metal, like it wasn't even sticking. The scuff marks are from steel wool just before I sealed it. This is one of the main areas that makes the seat belt wet along with the cracks at the top corners of the roof
I would also go over the washer nozzle and wiring harness grommet by removing them and applying weather strip adhesive or silicone rtv before installing. Make sure all the old debris and water is removed with brake clean/solvent and compressed air before applying any adhesive
Does anyone know if the hinge areas also crack near the other side of the hinge since mine didn't show any signs of cracking yet. I also removed the hatch spoiler to access the roof easier but isn't necessary and will require you to use new clips, if the rubber spoiler strip gets in the way you can place a piece of folded cardboard under it to lift it away from the glue area when repairing the hinge area cracks.