2004 Mazda 6, "infamous" trunk leak - Focus Fanatics
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Old 12-24-2012, 03:55 AM   #1
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2004 Mazda 6, "infamous" trunk leak

I've had my 6 for a couple months now, I noticed after the first month during the rainy season it had a slight leak somewhere in the trunk. I dried it up hoping it was due to me having the trunk open during a down pour when i had my jumper cables out to jump my focus.

needless to say after a couple weeks I forgot about it, me and my wife started to notice a bad "mold" smell. I checked all over the car and found about a quarter inch of standing water in the spare tire well, and the jack hole was very wet and was growing mold. I again dried it all up and cleaned up mold the best I could with bleach. I noticed the one of the two rubber plugs in the bottom of the tire well was missing and someone covered it up with tape. Although it seemed as if the tape was actually holding there was still water. I pulled the tape up thinking I had a extra plug from my old ranger laying around. turns out I didn't so I used a couple vinyl decals I had lying around to cover it again till I could source a new plug.

Long story short I couldn't find one any where, even figured one of the local parts stores would have a universal one but no luck. So today I decided to figure something out cause the smell is returning and this winter is going to suck.

So I bought a couple tire repair kits and a rubber master cylinder seal the same size as the hole I needed to fill.

You can see the wet tire well, missing rubber seal and my temp fix, plus the moist moldy jack area.

I then dried up all the moisture and scraped up the black coating, it had water under it and was coming up anyways. I wanted to make sure I got it all dried up too.

The driver side hole had a better flat surface underneath so I decided to use that side as to repair and use the factory plug on the passenger side. i cleaned all the mounting surfaces to ensure a good rubber glue bond. Just in case it too was leaking I use rubber sealant on the factory plug before re-installing.

I then used the rubber sealant and applied it all around the plug to help seal it better.

I then did the same treatment to the master cylinder "plug". Because it doesn't actually "snap" into place like the factory plug does I used the tire patch to help as a double seal.

I then moved on to the jack area. I took all the carpet out to try to source the cause of this leak. after about of hour of search every nook and cranny, including around the rear window I decided to pull out the hose coming down from the roof area, which I think is a drain hose.When I pulled it out it had moisture all around it on the inside so it had to be the source. I also cleaned around the hole and applied a smaller tire seal. Took razor blade made a X in it to allow the hose to pass through making a better seal.

I then put the trunk back together, now I wait a couple days to see if the seals hold up and to see if I still get water build up in the trunk.

I let the car sit for a few hours inside to make sure everything dried.

Do one thing every day that scares you. -Eleanor Roosevelt
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Old 12-24-2012, 05:50 AM   #2
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Good job man! Thanks for sharing.
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