How to close the gap between the door panel and the door shell?

[nuviper]

Hi guys,

I have own my cars about 1 year and put about 10000 miles on it. It runs perfect except for one issue that is a little annoying: my passenger window control module has broken three times. I was taken care of by the dealership under warranty but it was still very frustrating especially when you were cruising while the window came down automatically and never came back. All of them happened after the rain so I decided to look into it a little to see what happens. I got the recent broken control module, open the plastic cover and saw a sign of water on one of the resistance on the electric board. After examined and compared the passenger door with the good driver door, I found out that there was actually a small gap between the leather door panel and the metal door shell on the passenger side. I could actually see the wire and plug for the control module even though the panel was already installed. The driver side doesn't have this gap. I suspect that the water will flow into the gap and then into our non-waterproof control module and make the short circuit happen when the rain is a little heavy...

So my question is: is there a way to close the gap between the door panel and the door shell? Or is there a way to make the electric system in the door more waterproof?

Thanks for reading.
Nuviper

[Topplayer]

can you provide a few pictures?
Might help people understand exactly where you are talking about.

[swexlin]

I have the same gap, passenger side. My whole panel came loose once, broken pin, was fixed, but still not quite right. Driver side much better. Let us know what you find.

[BJG32]

Maybe just waterproof that module?

[SSGNRDZ_28]

Good troubleshooting efforts. Can you post a picture of the module?

[nuviper]

Sorry guys. Just got the car from the dealership yesterday and here are the pictures of the things I said. I will add one more picture of the water sign on the electric board later on. It's on my friend's phone. (seems that some pics are rotated)

First picture is the gap between the panel and the door shell (see below). If you use a torch light, you will see the wires connected with the control module...Although this is inside the car, I doubt that under a heavy rain, water will come through the rubber seal between the door and the body and flow into this gap.
IMG_8033.jpg

Second thing is the control module. The electric board is inside the black box. The box has no water seal itself. After the dealer helped me to replace a new module yesterday under warranty, I did the water-proof work with the silicone sealant with my friend (see below).
FullSizeRender.jpgIMG_8036.jpg

After we finished the water-proof work above, to double the security, we fill the gap between the panel with the sealant, not only on the passenger side, but also the driver side to secure that the water will not leak in this way (see below). This sealant is not good looking but it can resist water and it's rather easy to remove if you don't like them.
IMG_8039.jpgIMG_8040.jpg

I will drive from Germantown, Maryland back to Chicago this weekend. Seems there will be a thunderstorm...it's a good chance to test this water-proof work and hopefully I won't need to drive all the way back with my windows open.

[nuviper]

Pics added..sorry for late reply.

[nuviper]

Hi Swexlin, currently I just fill the gap with the sealant for water proof. But this may not be what you want...

- - - Updated - - -

Hi BJG32, thanks for your advice. I waterproof both the module and the gap. Hope it will hold some time

[nuviper]

Hi SSGNRDZ_28, I posted a picture about the module with waterproof sealant...I will post the picture of the broken circuit board later on.