I should add, I have the access cab model. When we compared it to one of the quad cabs that belonged to one of the maintenance technicians, it had a little leakage on the back windows of the quad cab doors as well.

 

First of all, welcome aboard. We don't bite around here.

You said that you had the system going full blast. On full it is bringing in a large volume of air from the outside. The air has to go somewhere, most through the exit vents, but these probably can handle a little less than the amount coming in on full so the air seeks other places to flow out.

As far as the water, I have opened both doors after washing and get water out the bottom of the door. There is a plastic sheet just on the other side of the panel and I think the design is to keep water away from the panel. Seems like there may also be a drain hole or two around the bottom of the door. I'll have to take a peek to confirm.

They weren't using black silicone in there were they?? That stuff can make an extreme mess.

 

Thanks for the welcome and reply.

It was some sort of clear lubricant/sealant they used. It was a horrible experience from the dealer. First the part wasn't ordered so I had to reschedule. Then the work was done and the problem wasn't fixed. Stains on my seat and this silicone lubricant stuff on the inner trim. Then I was told they weren't going to clean it because there was no proof that they made the mess. It took me walking into the owners office to have the issue rectified. His service manager was withholding a lot of information about my case from him. The owner wasn't pleased, and he detailed my car with all of the e-mails I provided him between me and the service manager showing the extent of the battle I had with him to make it right.

I figured there would be air leakage from the cab from somewhere, but from that particular location seems rather bad. It also leaks from that spot when at low fan speed. I've only yielded movement on a peacock feather though so it is very minute at low fan speed.

 

Wow, another dealer horror story. I quit going to the dealer even for a lot of warranty stuff.

 

Oh, and on your picture, air leakage seems to occur rather often at the top of that frame at the next corner above where you circled.

 

What Taco'09 said in Post #3

Water goes down into the door. A lot. The plastic liner is to keep it away from the fiberboard that makes up the door inner skin.

I used to worry about this, until I took a door apart once. Getting that plastic skin back together in one piece is far more important than stopping the water ingress. I opened a friend's door once to look at a broken door lock, there was still water inside the door on the window actuator assy.

The worst part is, your dealer probably made it worse than it was.

 

When they replaced the trim the first time, it was so terrible that I had to go back and get them to replace the passenger side again because the rubber wasn't connected together under this coupling like rubber molding piece. it was literally 1/4" out of the connector.

As long as there isn't need to worry, I won't let the issue bother me anymore.

 

I wouldn't worry about it. Water intrusion into the door itself is normal. And there are air holes where the plastic is open to allow the lock and latch rods to go through (from handle interior side of water barrier plastic to the outside to the door latch hardware).

Our trucks are not nearly as airtight as a highlander for instance. You can tell by driving at highway speeds, turning the airflow setting to recirc with fan off, then holding the back of your hand around places like the door handles or windows. You'll feel it blowing in. Turning the blower on with recirc off reverses that flow of air out the vehicle and past the seals. As for water drains, all vehicles have multiple drains in bottom of the doors. They were there in the 70s and are still there today.