Just a quick update - more investigations have shown that my Fusion has at least 2 leaks, both into the passenger footwell.

Leak 1 is coming from an internal sealant type joint about half way up the angled section of the footwell. It is only like a pin prick but lots of water is getting through.

Leak 2 is coming from the extreme left hand side under the windscreen heeater vents fascia, from inside a box section that appears to run across to the other side.

Both of these leaks seem to be seen when water is poured down the passenger side of the windscreen. I have removed the plastic thing along the bottom of the windscreen (I think it is called a scuttle). under this is a flimsy seal that water is getting behind.

Will try a letter to Ford hopefully to get these problems sorted under warranty (fingers crossed).

So pleased you have managed to find the leaks !!! and two as well !!

Sounds like a quality problem they have had.

With the car being so new, i would think they aught to carry out the repairs free of charge.

It may also be worth looking to see if any corrosion has taken place, in fact this might be your fight with them, is there not a corrosion warranty?

Best of luck with your car.

Paul.

Cheers for that paul - i'll keep you posted