Page Revised: 10 June 2019
Like many vehicles from the 1980s, we are at the point where some things on our cars might need replacement and there's no better example of that than with the weatherstripping. These rubber pieces are all that keep the rain and elements out of the car, while keeping comfortable air in. And generally our cars tended to have good weatherstripping from the factory; the water channeled out in key areas, and the cars were quiet enough for their time. But maybe you've noticed some air or water infiltration. Or perhaps some parts are torn or missing. This section should help you make informed decisions about replacing the weatherstripping across your car. We'll start toward the front of the vehicle then move toward the back. The information below is for all 1983-88 Cougars and Thunderbirds, except where noted.Weatherstripping is expensive—we're talking maybe more than what you paid for your entire car.
A word of caution before starting: as generally seems to be the case with all vehicles, weatherstripping is expensive. Like, we're talking maybe more than what you paid for your entire car. Unfortunately there seems to be no magic shortcut or good deals on replacement weatherstripping. It is going to cost you. As long as you are prepared for this going forward, the sticker shock will be a little more tolerable.
Note: Photos coming soon!
You should have two main seals in the hood area. One is the hood-to-header panel seal, an approx. 1" thin, semi-rigid piece that's held on the header panel with several screws. A lot of times this piece will rip or tear near the latch area. Or sometimes it's missing altogether, as the screw holes are fiberglass and can snap off. Or perhaps the header panel was replaced and the piece is just plain gone. Technically it's an air deflector that helps funnel air back to the radiator; however, water will just drip out of the front bumper cover without it. But it does keep the headlight wiring protected from excess water and ice. You should consider having this piece if possible. New replacement seals are available.
The other main seal is the hood-to-cowl seal and again, its job is to keep water from running into the engine bay from the windshield and cowl area. There are about 12 nylon pins that hold it to the hood, and they can easily rip the weatherstrip. These pieces are available new, and the same one was used on the Cougar, Thunderbird, and Mark VII.
There are some other, smaller pieces under the hood as well. The hood-to-fender pieces keep water from getting around the hinges near the cowl area (original part numbers were E3SZ-16071-B and E3SZ-16072-B). These pieces are available new. Also, you have a few front fender apron seals and front fender splash shields hanging around your lower front engine compartment. They are technically not "seals" but they do keep water and road grime front getting into the engine bay from the wheel wells. These rarely deteriorate or tear, but they can go missing due to lost fasteners. These are also available new (some minor trimming may possibly be needed).
Last, there are four hood bumpers that slide into slots on the hood. They keep the hood floating above the fenders. Again, they rarely go bad or missing, but new ones are available and should be identical to those used on Fox Mustangs.
Front Door, Outer
The beltline molding (aka "dew wipe") is one of the most commonly broken pieces of weatherstripping on the entire car, mainly because it's the only one that's really on the outside and relatively unprotected. Water, ice, and sun damage are very common. The main function of this piece is to keep water out of the door. With each time the window is rolled up or down, this piece will "wipe" the outer window and wick water away from the interior. Some water, in normal use, will still drip into the door itself and find its way out of the drain holes; that's considered normal. But with broken weatherstripping here, you can imagine what happens—excess water will lay in the bottom of the door and cause rust rather quickly. And that can be downright disastrous.
For 1983-86 cars there is some good news. Technically you can remove your beltline trim piece and take off the old outer molding. From the factory it's held on by staples; on replacement it will likely need held on by pop rivets, which may mean drilling some holes, but they won't be seen in normal use. And it doesn't matter if you have a vent window or not—the molding can be modified for either door style. Replacement beltline molding varies; we still have not come across the exact factory style, although there is some good universal stuff out there that will do the job. A few people have mentioned the Fairchild brand from Rock Auto, and we've also used this style before with acceptable results. It's a universal piece that's cut-to-fit. Of all the weatherstripping on the entire car, this piece seems to be the most inexpensive to replace using this universal piece.
We've also discovered beltline kits offered by Restoration Specialties & Supply, Inc. for a pretty decent overall price, considering it's an 8-piece kit.
Unfortunately for 1987-88 owners, the dew wipe is part of the beltline trim piece and cannot be separated. Replacing the dew wipe requires replacing the entire beltline trim. We do not know of anyone selling anything that will help you. You will need to find good, used pieces to replace yours in your car's style.
Front Door, Inner
First up, we have the window channel run which is exactly what it says: a channel inside which the window glass slides up and down. This part is unique in that it is exposed on both the exterior and interior, therefore there's double the chance that it can rot. We've seen some photos of this piece from cars in the southern U.S. and beyond, and the cracking is just unbelievable.
So the good news is that the window channel run is available new (again: it's expensive). Our cars had channel runs that are very, VERY similar to other Ford cars of the era and that's led to people trying out alternative solutions. Mustang channel runs are a bit short but can work. Similarly, Ford Tempo/Mercury Topaz 2-door channel runs can work but only if you have the optional vent window, because it's also a tad shorter. Personally, I've used early Ford Ranger channel runs before with great results in my vent window car. And this part is shared with the Mark VII so that's yet another option. Right now there are a few people working on some solutions and when/if we get new info, we'll be sure to post that here.
Speaking of the vent window, there is a unique perimeter seal around the glass that is more or less one-piece in nature. We are unsure if that part is separate or part of the entire assembly. Replacement may need to be with the entire glass structure. More info here as it becomes available. See the Vent Window Latch Repair section for additional details.
Next we have the drip rail molding which channels water away from the interior and also makes sure you don't get a sudden downpour of water when you open the door. Generally they hold up well, although they can tear with age and extended use. Drip rails are available new.
The inner belt molding is just like the outer beltline molding except on the interior of the car. It easily pops out of the door when the window is down, and is only held in by built-in clips. On all cars, there was a chrome top piece inset into it. These inner belt moldings are available new, usually as a pair.
There is an upper door seal which is clipped in the front portion of the door, where it meets the A-pillar. Again, these usually do not get damaged but can rarely pop out and go missing. They are available new and are frightfully expensive. This part was also shared with the Mark VII.
And there is a lower door seal on the underside of the door that's held in by about 10 nylon pins. This seal keeps water and air from intruding through the lower door gap and into the car. Sometimes it can get torn, or even go missing if it's kicked enough times. It is available new and was shared with the Mark VII.
Finally, you can indeed get a kit which includes the more popular weatherstrip parts mentioned above. That might save you some time and effort. You may also need to sell your plasma and firstborn child to afford it.
Perhaps the most important inner seal, the inside door perimeter seal is the main barrier between the outside and your interior. The door closes upon it, after all. Therefore it's very susceptible to rips and tears, particularly where your feet will swipe the sill plate upon entry/exit from the car. Sometimes minor rips and tears and even some holes can be repaired using a good weatherstrip adhesive, and that's fine. But if yours is beyond that sort of help, there's good news: new perimeter seal weatherstrip is available. It's not cheap, we will again iterate. It was a common part used in the Cougar, Thunderbird, and Mark VII.
If you have a factory sunroof (flip up only), there is a sunroof seal that greatly helps with water and air infiltration. Also there is a seal that goes on the body that's identical to those used on other Fords of the era, including the Mustang. Please see the Glass Restoration & Replacement section for more details.
Similarly, you may want to replace your power moonroof seal. It is also available new through Sunroof Doctor.
Last, we have found a new trunk seal to help tremendously with water intrusion. Generally they don't normally get all torn up but they can compress over time, which leads to air and water infiltration in some cases. We've found news ones at Stock Interiors, among others, for a decent price.
There are seals between the taillights and the rear attachment panel. The seals are circular in shape, pre-molded, and are considered part of the taillight housing assembly. On rare occasions they can fail and let water into the taillights. Sometimes they're just distorted but other times they will split at the factory seam. We have seen them sold separately but can't seem to find any part numbers or vendors at this point. If you need to replace them, you might consider getting new taillight housings and swapping those seals into yours.
Other miscellaneous rubber parts, like the hood, trunk, and door bumpers, are available new and are generally inexpensive. They're not really seals, but they do help keep things quiet and performing like new.
Where To Buy
So where exactly can you find these new parts? Until a few years ago, finding weatherstripping was pretty difficult and scattered amongst vendors on the Internet. That is, until Steele Rubber Products came along and started producing pieces for our cars. Because the general shape of a majority of the weatherstripping was similar to other Fords of the era, it was probably easy enough to get them into production (in particular, we likely have the Mark VII to thank for parts availability here). Steele seems to carry pretty much all of the weatherstripping mentioned above. We have no affiliation with them, just want everyone to know that they're a long-known trusted name in the auto restoration business that has finally begun to fill a need for our cars.
Interstingly, a company called Classique Cars Unlimited seems to sell the identical parts as Steele but for a bit less cost. And they take Paypal.
Some of the other odds-and-ends vendors have been linked in the sections above, as required. Should you find another vendor for weatherstripping please don't be afraid to let us know.