Headliner leak issue found
I realize this is an old post but just thought I can add to this after having the same issue. My father has given me his 93 that is pristine in condition never having seen a winter here in Canada. Rust was not an issue. The carpet had almost an algae / mold smell to it. I have literally pulled the interior completely out seats, carpet, all plastics, headliner. In my quest I had taken the truck to have the back window removed and then put back in using urethane by my local glass shop. Came home and the next rain..water and when I removed the headliner it was wet in the drivers side upper corner....above the window. After taking it back to the glass shop the guys there found a couple of things....the roof / cab back seam was open for over an inch...you could shine a light from inside to outside ...problem one...The other issue was in the same body seam line there was a crack that ran all the way up and under the extended cab rain trough gutter insert which was allowing water to get inside the cab wetting the headliner. The crack and open joint can't be seen from inside the cab due to a double wall construction on the back of the cab and roof area. I plan on sealing it up with some urethane for the larger open seam and then using some thin flowable sealer of some sort that will creep into the small crack that runs up under the insert in the rain gutter. That should fix all the leaks.....I hope.
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