I wonder if beefing up the structure around the window would help, and then "floating" the window in the opening?
Of course, the cost for that would be far more than a new window. Guess FCA will just keep swapping glass...
The window is a bad part from the supplier (unless
both manufacturers are doing something wrong on the assembly line). GM uses the same supplier and those guys are having the same issue we are.
I also had leaks without visible cracks that my dealer sealed up, waiting for the cracks to become visible to have it replaced with the new updated window assembly.
Mine initially were almost invisible. When it rained and I noticed the moisture I parked on an uneven surface to articulate the suspension and "twist" the truck. This made the crack noticeable and I snapped some pictures to show the service guy when I took the truck in.
That worked in my favor as the dealership lot is flat at the service section so the pictures painted a different picture than what the service writer saw (even though the STAR Case has you run your fingernail across the blemish to determine if it's a crack or seam). The pictures made it a slam dunk for approval.
If yours doesn't have any visible cracks, it may be possible it is the high mounted break light or the shark fin antenna that is the source of your leak.
That will usually result in a wet headliner as well. The window frame crack will start at the window (obviously) and drip down the back of the cab (and possibly the rear bench depending on how bad the leak is).
I'm not sure if they remove the CHSML for the window replacement but once you break that initial seal from the factory it seems to be more miss than hit for the CHSML gasket to re-seal.
Mine is leaking, no cracks visible anywhere. Waiting for window to come in - 2 weeks now. I have the truck and can't garage it. If it starts getting worse I'm going back to dealer for some help on how to keep it under cover.
My truck lives outside.
It was over a month between noticing the crack, getting the repair approved, and having the rear window replaced. I had a couple of old bath towels that I used to wedge between the rear bench and window frame to soak up the water. I would put one back there and when it started to feel damp I swapped it with the other one so I always had a dry towel in there to prevent any long-term moisture damage.