I have had the infamous "water dripping from dome light problem after applying the brakes" for FIVE YEARS! Dealer tried to fix it three times with various TSBs and other ways, but it always came back. I figured it was a piss-poor design problem of some kind, and just lived with it; I wasn't about to pay after the warranty expired. THEN it recently got a whole lot worse and soaked the floormat behind the drivers seat. I never had it leak there before, so I decided--come hell or high water-- I was going to figure out what was going on.

Background: I had done leak tests on the sunroof drainage rails previously, but never found any of the four drain lines plugged, or faulty. But after any substantial rain, with my car parked on a slight incline to the rear, I would invariably discover water dripping from the front dome light after a few minutes of driving, once I applied the brakes. But never any signs of water stains or leaks on the headliner. Like I said, that went on for years. NOW, after dropping part of the headliner so I could see all the plumbing, etc that was attached to the sunroof frame, I retested the drain system by slowly running water into the drain rails, and shining a bright flashlight everywhere I could see. Voila!! I immediately saw water dripping from a seam at the rear of the frame assembly, on the driver side. It was coming from where the plastic rear gutter assembly fastened to the aluminum frame. The dripping water was pooling in one of the rear headliner recess areas, just behind the driver's head! Guess what happens when you drive away, and then put on the brakes, or start descending from a hill; you get rain, delivered from the easiest place for the water to leak out---the dome light!!! I took it back to the dealer today, and insisted that it get fixed--correctly this time. Looks like they will do it for free. I just hope my curtain airbag wasn't damaged, because I know it got wet--many times.

That's my story, hope it helps some of these other folks.

Update from Feb 13, 2012: Took car to dealership last week, along with history of attempted fixes, AND a video of where the water was actually coming from. Even though the car was three years out of warranty, they agreed to fix the problem at no charge (once I spoke with the Service Manager). I am certain that this problem exists with other Explorers and Mountaineers, and even Aviators of the 2004 through 2007 model years, maybe others as well. They sealed the rear seam where the sunroof side rails are connected to the rear plastic gutter assembly, which has two drainage hoses attached to it. Problem solved---REALLY.

Rain water started leaking in at the interior lights about 4 months after we purchased this vehicle BRAND NEW! Took it for repairs only to be told the drainage tubes were blocked. Okay problem solved right? UMMM NO!! Back again, same problem, few weeks later. This time told (and I quote) "you were obviously throwing some cookies out the sun roof and one got hung in the drainage tube". I HAD NEVER EVEN USED THE SUNROOF! Few months later... same problem! Took it in and was told they could find no problem. Problem kept happening! Waited a few months then tried again. This time told warranty wouldn't cover it. So I called dealership owner.... Warranty covered it. Here we are 11/09.... same problem only worse! Took it back to dealership last week... drainage stopped up again they say. HMMM Guess I've been eating to many cookies!