I noted the same exact thing when I tried to put my old trusty Thule rack on my '98 V70AWD, using the proper foot kits of course. The way the feet clamp around the roof and fit under the door gasket allows water to come in under the gasket and drip down inside the car. I removed the rack and put it on my Subaru instead. I never tried it on the Volvo again. So much for the great Volvo/Thule partnership.

I hope someone comes up with a decent solution for this problem. I have read other messages from people with the same problem.