After finding a damp patch in the passenger footwell I Took my 59 plate to the dealer. £120 to have the sunroof drainage rectified. once back and after a heavy bout of rain found both passenger and driver footwell water logged. Water literally sitting on the surface. Took back to dealer to be told its the windscreen sealant worn. £500 to fix because of a stone chip on the screen may result in the screen breaking on removal. Luckily replaced on insurance. Now hoping for dry footwells

Did these problems occur on cars built while it was a Ford made car with a Volvo badge?

Looks as if they are mainly 2009 cars was this when Ford owned Volvo I think so will say no more I am sure to be informed if I am wrong!

I think the bonding issue is due to the modern method of relying on a bonding resin to be the main thing that holds the screen in place. My XC a 2010 car leaked from the windscreen and I was most surprised by how many people had had a similar problem. The way of testing to see if your screens are going to leak is to stand outside the car with the driver or passenger door open and push the screen outwards and look for movement at the top of the screen. If you notice movement then remove the trims holding the carpet and lift so you can feel underneath the carpet which has a thick foam backing. You wont notice a leak until there has been a good deal of water collected under the carpet as the foam acts as a sponge. If your screen is leaking use duck/gaffer tape to form a repair until a permanent solution.

This seems to be alarming since the windshield construct also determines the strenght of the safetycage of the car

Hi, I also had a leak but couldn't identify where it was coming from. Water in the passenger foot well. However a large stone picked up from a lorry ended the windscreen. The windscreen fitter asked if I had had a leak as the top of the windscreen was unstuck. New windscreen courtesy of the insurance and no leak. It would appear that Volvo didn't do a good job in the first place. Rather disappointed on a quality car.

Right, to dispose of some of the comments here

The sealant doesn't wear,
It's a moisture curing Polyurethane. As with all glazing systems it can leak if not applied correctly, if the glass is moved before being fully cured, causing rat holes in the seal, if the primer coat onto the body frame us not applied correctly or not at all, or the body is not straight, has ridges from welding, or the bead profile is not controlled, due to humidity or heat.

However, as a sealing method, it is much better than the old rubber bead system, is stronger and becomes part of the ridgidity of the vehicle, enabling smaller A post profiles and us more aerodynamic.

By the sounds of it, as it seems to be effecting a range of cars from one particular time in the majority of cases, I would say it was contamination if the primer or the PU was skinning too quickly, due to manufacturing issues

Most owners of leaking screens put their trust in the modern method of bonding the screen to the vehicle and probably wouldnt question what method is more reliable. I have never in nearly 40 years of owning various vehicles had a windscreen leak like my car has. If the failure of the bonding is a safety issue it would surely have involved a recall. I would assume that many owners dont know they have a badly bonded screen because until the damp patches are noticed they will continue driving with complete ignorance. If the materials used to fix the screen in place arent up to the job or have been applied wrongly I think it is only fair that owners are informed that their screen bonding may have failed or is likely to fail and put right the problem.

The XC60 has always been made in the Volvo factory in Ghent Belgium. Not really relevant who the company owner was in this case. More the fact it was the year of introduction I think. Not unusual for a new design to need modification to a few components further down the line.

I'm not aware of ford windscreens leaking.