Seals

Maintaining Rubber Seals

This article comes from various PM's and discussions on maintaining the bonnet seal on the D3 to prevent water ingress behind the battery fuse box which can then cause damage to the transfer box ECU.

First over time small particles, dirt and foreign bodies will enter into rubber seals. With more time more debris enters and the seal can be elevated from the material it is meant to be sealing. Given enough debris/time then water may be able to pass drop by drop or relatively freely.

The solution covers the case where the seal is undamaged and otherwise operational if it were not for the debris contained within it. A seal that is stuck should be investigate and rectified so that it may be moved freely - it is not advised to simply apply more force as this may damage the seal or induce more force on the member than the design caters for (i.e. damage something else).

Use a cover (cloth, towel, etc.) in the area to prevent debris falling around the area of work. If the seal comes away freely then remove part of the seal and using a lint free cloth to remove the debris from above, to the side and below the member. Take care not to apply too much force, as sharp debris may scratch the surface finish. Using a thin item (fine screw driver, steel ruler, etc.) and covered with clean cloth run it gently down the seal removing any debris within the seal. Repeat until cloth is debris free.

Refit the seal in the area ensuring it presses fully home. Work on the next section of seal.

If preferred the whole seal can be removed and worked on in whole but it in my experience it takes more time and is harder to refit a complete seal than work on it in situ in parts.