Volkswagen T6.1 Ocean Roof Seal Replacement — Gap and Rust Concerns

[meiyu107]

“Is it normal for there to be a gap after replacing the roof seal on a T6.1 Ocean? Could it lead to rust problems?”

 

[sidepod]

No that’s not right! Looks like it just needs pushing on properly?

 

[KevH]

Any seal that doesn’t actually seal will allow moisture to ingress.
That seal looks ‘wavy’ on the folded edge suggesting that it is not pushed on enough. It isn’t a task I have myself so I can’t offer any tips however I would give it some priority or risk trapping any moisture already in there.

 

[Van Diesel VW]

“Is it normal for there to be a gap after replacing the roof seal on a T6.1 Ocean? Could it lead to rust problems?”

View attachment 139629

Why was the seal replaced and if at a garage I would return and advise on a faulty install.

 

[sidepod]

FFS. Raise the roof a couple of inches, stand on the door foot step and push it back on.

 

[Viktorgeorge]

I have had three of these seals over 2 years and none of them fit perfectly at this specific area, but all certainly fit better than your photo. Elsewhere on the pop up roof the fit is tight.

One of the problems with this section of the seal is that it has to be moulded to the two ‘ridges’ at the front, but whilst the seal has an integral steel ‘spine’ to help it hold its shape, that steel spine is also a potential rust problem as it easily breaks through the rubber.

Fitting a new seal therefore requires great care and is best done it hot conditions. My experiences are described within a separate string, which is full of useful information from forum members:

Post in thread 'Avoiding roof corrosion?'
https://vwcaliforniaclub.com/threads/avoiding-roof-corrosion.22428/post-641856

 

[Kayleigh]

“Is it normal for there to be a gap after replacing the roof seal on a T6.1 Ocean? Could it lead to rust problems?”

No it’s not normal, but also not normal for a T6.1 to need a new roof seal I would say.

 

[Viktorgeorge]

No it’s not normal, but also not normal for a T6.1 to need a new roof seal I would say.

@Kayleigh, I had three different seals within a year and I recall @Perfectos had even more!

The rubber element is much longer lasting but if the seal is handled wrongly (as mine proved to be, twice) it needs replacing. I have also found, two years on, that my procedure of tape to the front roof edge and annual seal removal (when in warm sunshine) cleaning and light brushing in of Lanoguard grease - all as per the link in my previous post - has kept my seal problem free for the last two years.

There does seem to have been more of a problem with recent seals. I recall that @WelshGas checked his seal annually for 12 years or so without corrosion issues.

If for example you get firm with one of the current seals using a rubber hammer to shape it around the front ‘bumps’ in the roof I can guarantee you will reap the consequences.

Careful removal when warm, and then close scrutiny of the inside groove of the seal particularly the front part, to see if there is any ‘break out’ of the steel reinforcing spine would be my advice to anyone who wants to reduce the risk of roof corrosion later. And of course careful replacement afterwards ideally with the front roof edge taped (VW do a tape* and I will check for the reference number though electrical tape is probably just as good) and something like Lanoguard grease.

*Added:

The tape appears as ‘protective film’ under reference 35. Her are some links:

https://www.lllparts.co.uk/catalogs/vw/RDW/CAMP/1058/8/875/875010

Protective Film Make Up D448S22A2 New Genuine part

Deutscheparts specialise in the supply of genuine car parts & accesories for Volkswagen, Audi, Skoda and Seat cars and vans.

www.deutsche-parts.co.uk

I would not be surprised if, in a few years time, this forum is replete with later T6.1 California discovering bubbling paint etc. on the edge of their aluminium pop top roofs. The problem is so obviously waiting to happen.

 

[sidepod]

The roof edges are taped from the factory.

 

[Kayleigh]

@Kayleigh, I had three different seals within a year and I recall @Perfectos had even more!

The rubber element is much longer lasting but if the seal is handled wrongly (as mine proved to be, twice) it needs replacing. I have also found, two years on, that my procedure of tape to the front roof edge and annual seal removal (when in warm sunshine) cleaning and light brushing in of Lanoguard grease - all as per the link in my previous post - has kept my seal problem free for the last two years.

There does seem to have been more of a problem with recent seals. I recall that @WelshGas checked his seal annually for 12 years or so without corrosion issues.

If for example you get firm with one of the current seals using a rubber hammer to shape it around the front ‘bumps’ in the roof I can guarantee you will reap the consequences.

Careful removal when warm, and then close scrutiny of the inside groove of the seal particularly the front part, to see if there is any ‘break out’ of the steel reinforcing spine would be my advice to anyone who wants to reduce the risk of roof corrosion later. And of course careful replacement afterwards ideally with the front roof edge taped (VW do a tape* and I will check for the reference number though electrical tape is probably just as good) and something like Lanoguard grease.

*Added:

The tape appears as ‘protective film’ under reference 35. Her are some links:

https://www.lllparts.co.uk/catalogs/vw/RDW/CAMP/1058/8/875/875010

View attachment 139655

Protective Film Make Up D448S22A2 New Genuine part

Deutscheparts specialise in the supply of genuine car parts & accesories for Volkswagen, Audi, Skoda and Seat cars and vans.

www.deutsche-parts.co.uk

I would not be surprised if, in a few years time, this forum is replete with later T6.1 California discovering bubbling paint etc. on the edge of their aluminium pop top roofs. The problem is so obviously waiting to happen.

Thanks for commenting. Hadn’t realised it could be so bad with later Californias as the front is taped. I guess the real problem is that without regular checks it’s hard to tell if there is a problem until it’s too late. But the more you check the more chance there is of damaging the existing seal, hence the replacement.

 

[Viktorgeorge]

The roof edges are taped from the factory.

Sorry, @sidepod you are wrong on that point. On mine the front edge had no tape (or protective film as VW call it) only the back and sides. From other posts mine was the normal, though perhaps vans more recent than MY23 have that corrected.

 

[Viktorgeorge]

Thanks for commenting. Hadn’t realised it could be so bad with later Californias as the front is taped. I guess the real problem is that without regular checks it’s hard to tell if there is a problem until it’s too late. But the more you check the more chance there is of damaging the existing seal, hence the replacement.

I am definitely in disagreement mode today @Kayleigh!

I think the more you check, clean and treat the seal, carefully along the lines I suggest, the better your chances are of avoiding the problems. @WelshGas (aka the sage) made an interesting a point a whilst back, suggesting that regular treatment of the seal to avoid it adhering to the roof below the pop top might be helpful. His suggestion being that perhaps if the seal starts to attach itself to the roof below, then roof operation will cause the seal to slip a little and with dust and grit be abrasive on the aluminium etc. etc.

I tried to find that @WelshGas post but failed, I suspect he put it better than me. A search under ’Roof Corrosion’ yields many results.

 

[WelshGas]

I am definitely in disagreement mode today @Kayleigh!

I think the more you check, clean and treat the seal, carefully along the lines I suggest, the better your chances are of avoiding the problems. @WelshGas (aka the sage) made an interesting a point a whilst back, suggesting that regular treatment of the seal to avoid it adhering to the roof below the pop top might be helpful. His suggestion being that perhaps if the seal starts to attach itself to the roof below, then roof operation will cause the seal to slip a little and with dust and grit be abrasive on the aluminium etc. etc.

I tried to find that @WelshGas post but failed, I suspect he put it better than me. A search under ’Roof Corrosion’ yields many results.

It's me. Yes, when camping roof up, tree sap whatever on the roof where the rubber seal contacts can build up and basically glue the seal to the roof. When this happens opening the roof moves the seal until it is pulled off/up by the roof. Cleaning the area of contact using warm soapy water or Tar Remover, applying a good polish and also treating the seal, stops it adhering and the pull/push of the seal when opening/closing the roof.

 

[sidepod]

Tenuous ?

 

[sidepod]

I’ll happily bet the only vans that potentially have an issue, is those left outside in the elements 365.

Keep it under cover when not on use and all will be fine.

 

[Viktorgeorge]

Tenuous ?

It sure what you mean, @sidepod. There was nothing “tenuous” about the rusting seal reinforcement on my 7 month old Ocean. As per #80 on the link I posted above. I was sickened!

 

[sidepod]

It sure what you mean, @sidepod. There was nothing “tenuous” about the rusting seal reinforcement on my 7 month old Ocean. As per #80 on the link I posted above. I was sickened!

WGs theory is what I was referring to.

 

[Viktorgeorge]

I’ll happily bet the only vans that potentially have an issue, is those left outside in the elements 365.

Keep it under cover when not on use and all will be fine.

Mine was garaged for the first 7 months from new (October 2022 to May 2023), in the UK and Portugal, and I got the rust as per post #80, so sorry, but I sadly win that bet!

https://vwcaliforniaclub.com/threads/avoiding-roof-corrosion.22428/post-641856

Admittedly my ocean would have stood outside in the docks awaiting Europe to UK shipping before I collected it from the dealer but otherwise it was garaged (in superior well ventilated garage conditions).

I have noted this problem seems to be emerging on later T6.1, and perhaps the later seals are defective by comparison. My ‘tenuous’ guess is that the manufacturer or process of the roof seals changed. This could have been a change of the reinforcing material to a lower grade of mild steel or reduction in the depth of rubber cover over it. Alternatively the install of the seals at the factory (there is a tiny video clip see below) changed so that in first fitting the seals the damage sometimes occurred (this could explain my case).

Factory roof seal install at 5 minutes and 39 seconds (just 3 seconds long) here:

I will continue to do annual seal removal and cleaning etc as per my posts above and elsewhere on this subject, and suggest others (particularly of later Californias) might be advised to do the same, along of course with the essential roof drain maintenance described in other posts.

 

[WelshGas]

I’ll happily bet the only vans that potentially have an issue, is those left outside in the elements 365.

Keep it under cover when not on use and all will be fine.

Mine wasn’t garaged for 10 yrs. if not driving or camping it was on my drive and Wales is not renowned for its number of dry days.
So when it got wet it then dried out instead of sitting idle in a damp or humid garage for days on end.
No galvanic corrosion under the roof perimeter seal or on the windscreen panel when it was sold.