Pop top seal replacement

[Chris_569]

I need to replace the pop top roof seal (bit highlighted in the image). Does it just push on once the old one is removed or is there any adhesive/ sealant involved?
Thanks

 

[CaliforniaCylus]

Many posts on this already. Try this one.

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

“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?”

vwcaliforniaclub.com

 

[Perfectos]

Yes the roof seal pushes on to the edge of the roof panel.

Warranty? Dealer should replace

The seal will require shaping to match the front profile , do this by hand and gently push onto the edge of the roof.
do not hit the seal with your hand or any object to try and get it to seat (you will damage the seal inside the recess, which will expose the steel reinforcement and cause the seal to rust)

If there is any rust residue on the roof , from the old seal, make sure you remove every trace before fitting the new seal. (Including cleaning rust from the factory fitted tape) particularly if it is on the painted surface

Allow the roof edge / tape to dry fully before fitting the new seal.

dealers allow 24hrs with the old seal removed, to dry out, before fitting the new seal, appreciate the weather may not allow for this ATM, but dry it as best as possible before fitting the new seal.

A small spray of silicone lubricant applied into the seal recess will assist in fitting the new seal. (do not use anything other than silicone, it may deteriorate the rubber if it is petroleum based , silicone is safe to use on rubber)

Take your time and make sure the seal is fitted correctly before lowering the roof. The important bit is the front profile so it sits correctly. The bonded front corners are used to align the seal correctly on one side , working around to the other , do not stretch the seal excessively, remove and re fit to ensure it sits correctly at the front

Please post some pictures of the failed seal to assist others.

 

[Viktorgeorge]

@Perfectos has been generous here and elsewhere on other posts with advice about the pop top seal etc. It is well worth the time to search and study his and other posts on this subject. The downsides can get pretty serious from some posts here. I was very pleased to catch my problem in good time.

 

[Chris_569]

Many posts on this already. Try this one.

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

“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?”

vwcaliforniaclub.com

Thanks for finding this, I tried searching but didn’t turn up what I was looking for.

 

[Chris_569]

Yes the roof seal pushes on to the edge of the roof panel.

Warranty? Dealer should replace

The seal will require shaping to match the front profile , do this by hand and gently push onto the edge of the roof.
do not hit the seal with your hand or any object to try and get it to seat (you will damage the seal inside the recess, which will expose the steel reinforcement and cause the seal to rust)

If there is any rust residue on the roof , from the old seal, make sure you remove every trace before fitting the new seal. (Including cleaning rust from the factory fitted tape) particularly if it is on the painted surface

Allow the roof edge / tape to dry fully before fitting the new seal.

dealers allow 24hrs with the old seal removed, to dry out, before fitting the new seal, appreciate the weather may not allow for this ATM, but dry it as best as possible before fitting the new seal.

A small spray of silicone lubricant applied into the seal recess will assist in fitting the new seal. (do not use anything other than silicone, it may deteriorate the rubber if it is petroleum based , silicone is safe to use on rubber)

Take your time and make sure the seal is fitted correctly before lowering the roof. The important bit is the front profile so it sits correctly. The bonded front corners are used to align the seal correctly on one side , working around to the other , do not stretch the seal excessively, remove and re fit to ensure it sits correctly at the front

Please post some pictures of the failed seal to assist others.

Thanks for the comprehensive reply.

 

[Chris_569]

Yes the roof seal pushes on to the edge of the roof panel.

Warranty? Dealer should replace

The seal will require shaping to match the front profile , do this by hand and gently push onto the edge of the roof.
do not hit the seal with your hand or any object to try and get it to seat (you will damage the seal inside the recess, which will expose the steel reinforcement and cause the seal to rust)

If there is any rust residue on the roof , from the old seal, make sure you remove every trace before fitting the new seal. (Including cleaning rust from the factory fitted tape) particularly if it is on the painted surface

Allow the roof edge / tape to dry fully before fitting the new seal.

dealers allow 24hrs with the old seal removed, to dry out, before fitting the new seal, appreciate the weather may not allow for this ATM, but dry it as best as possible before fitting the new seal.

A small spray of silicone lubricant applied into the seal recess will assist in fitting the new seal. (do not use anything other than silicone, it may deteriorate the rubber if it is petroleum based , silicone is safe to use on rubber)

Take your time and make sure the seal is fitted correctly before lowering the roof. The important bit is the front profile so it sits correctly. The bonded front corners are used to align the seal correctly on one side , working around to the other , do not stretch the seal excessively, remove and re fit to ensure it sits correctly at the front

Please post some pictures of the failed seal to assist others.

Finally got round to this now ther has been a few sunny days so thought I’d report back.

Old seal - was not very flexible anymore after 18 years and as a result had some gaps around the changes in profile at the front of the roof and the awning. Van seemed to be getting increasing amounts of condensation in the winter which I have partly put down to more water getting under the roof. When I removed the old seal there were indeed some exposed steel reinforcement which was rusty, although this wasn’t yet causing the seal to deform excessively as some others have.

Roof - I was pleasantly surprised by the condition, a couple of minor paint bubbles below the seal. For good measure I have applied 3M tape to the edge.

New seal - fitted generally well, but I’m not happy with how it is sitting on the front. I think it is too high/has a gap at the rear. Having refitted a couple of times I have managed to improve it but it still isn’t as I would like it. It feels like it is fully seated and won’t push on further. Any suggestions or tips to get it to sit as it should?

Thanks

View attachment IMG_9483.jpeg

View attachment IMG_9481.jpeg

View attachment IMG_9485.jpeg

View attachment IMG_9492.jpeg

View attachment IMG_9495.jpeg

View attachment IMG_9494.jpeg

 

[Viktorgeorge]

Finally got round to this now ther has been a few sunny days so thought I’d report back.

Old seal - was not very flexible anymore after 18 years and as a result had some gaps around the changes in profile at the front of the roof and the awning. Van seemed to be getting increasing amounts of condensation in the winter which I have partly put down to more water getting under the roof. When I removed the old seal there were indeed some exposed steel reinforcement which was rusty, although this wasn’t yet causing the seal to deform excessively as some others have.

Roof - I was pleasantly surprised by the condition, a couple of minor paint bubbles below the seal. For good measure I have applied 3M tape to the edge.

New seal - fitted generally well, but I’m not happy with how it is sitting on the front. I think it is too high/has a gap at the rear. Having refitted a couple of times I have managed to improve it but it still isn’t as I would like it. It feels like it is fully seated and won’t push on further. Any suggestions or tips to get it to sit as it should?

Thanks

View attachment 146230

View attachment 146231

View attachment 146232

View attachment 146233

View attachment 146234

View attachment 146235

That seal fits as well as mine, which similarly is not perfect over the two front humps. Looks a good job to me.

 

[Chris_569]

That seal fits as well as mine, which similarly is not perfect over the two front humps. Looks a good job to me.

Had another go at this today. Got it fitting much better. It seems that along the front edge the helicopter tape is just thick enough to push the seal out so it doesn’t sit properly.

So I have removed it from the front edge. Elsewhere I think it is fine as the seal fits differently on the sides and back.

View attachment IMG_9524.jpeg

View attachment IMG_9521.jpeg

 

[Viktorgeorge]

Had another go at this today. Got it fitting much better. It seems that along the front edge the helicopter tape is just thick enough to push the seal out so it doesn’t sit properly.

So I have removed it from the front edge. Elsewhere I think it is fine as the seal fits differently on the sides and back.

View attachment 146658

View attachment 146659

That probably explains why VW did not tape the front edge on the pop tops (at least up until and including mine) only the other three sides.

I had not thought of that before, but remain slightly disappointed at my front edge over the humps. You have done noticeably better than me on that.

I am going to find it hard not to keep the protective tape I added to the front edge (the specific one VW list for the two sides and back), but you have a very good result without it.