A/C - Condensation Enters Passenger Compartment
9228ford02
Article No. 92-12-8
DATE: 06-03-92
AIR CONDITIONING-CONDENSATION (WATER DROPLETS) ENTERS INTO PASSENGER COMPARTMENT
THROUGH FLOOR DUCTS
FORD:
1989-93 THUNDERBIRD
LINCOLN-MERCURY:
1989-93 COUGAR
This TSB article is being republished in its entirety to extend the model year application through the 1993 model year.
ISSUE:
Water droplets in the air conditioning system may become airborne. Condensation forms into droplets which would follow the airstream as it flows through the system and out through the floor ducts into the passenger compartment. This occurs because there is a build-up of localized high velocity air in the evaporator case which moves water droplets toward the floor ducts.
ACTION:
Rework the evaporator case and install a baffle to prevent the build-up of high velocity air. Refer to the following procedure for modification and service details.
BAFFLE INSTALLATION
1. Using aluminum plate stock about 1/16" (1.6) thick, make the baffle shown in Figure 1.
a. The bend between the 5 1/4" (133mm) and the 1" (25.4mm) sides of the baffle is about 90 degree
b. The two 3/16" (4.8mm) diameter holes in the 1" (25.4mm) side of the baffle are provided for attaching the part to the evaporator case.
2. Squeeze the sides of the glove compartment assembly toward the center of the compartment to gain access to the evaporator case. This will free the attaching tabs at the upper rear corners of the assembly and allow it to be hung free.
3. Working through the glove compartment opening, cut a 1/16" (1.6mm) wide by 2 1/2" long slot in the evaporator case.
a. The size and location of the slot are shown in Figure 2.
b. The centerline of the slot is located 1 3/4" (44.5mm) back from the edge of the case and 1/4" (6.4mm) below the underside of the flange in the case.
c. Cut the slot into the case using a die grinder/cutting wheel or a series of drilled holes.
CAUTION:
WHEN SLIDING THE BAFFLE INTO THE SLOT, BE SURE THAT ITS ATTACHING FLANGE FACES TOWARD THE PASSENGER SIDE OF THE VEHICLE, FIGURE 2. IF THE FLANGE FACES TOWARD THE DRIVER'S SIDE, THE ATTACHING SCREWS COULD PUNCTURE THE EVAPORATOR CORE.
4. Install the two #10-12 X 1/2" self-tapping screws through the baffle and into the mating 3/16" (4.8mm) diameter holes which are to be made in the evaporator case using the baffle holes as a template.
5. Check the installation for vibration noise.
a. Turn the blower speed selector knob to its high position.
b. Operate the system in the MAX A/C, NORM A/C, and VENT function selections, c. If the vibration noise is detected in any of the three (3) functional selections, remove the baffle and bend it slightly to change the 90~angle at the bend. Make this change as the baffle is again being installed.
6. Check for any air leaks which may be caused by reworking the evaporator case. If any air leaks are located, seal them with black rope sealant (D6AZ-19560-A).
WARNING:
DO NOT USE A SILICONE SEALER BECAUSE IT COULD CAUSE EYE AND SKIN IRRITATION.
7. if sealing material is installed, check again for vibration noise. Refer to Step 5.
8. Install the glove compartment.
9. Test drive the vehicle. Include several right and hard left turns in the test to force any condensate, which may have accumulated in the case, to flow out through the floor ducts.
NOTE:
IF STEP 9 IS NOT TAKEN, SUBSEQUENT PASSING OF WATER DROPLETS FROM THE FLOOR DUCTS COULD BE A MISLEADING SIGN THAT ADDITION OF THE BAFFLE WAS AN INEFFECTIVE REPAIR.
FOLLOW-UP REWORK OF THE EVAPORATOR CASE
If the aluminum baffle, installed previously, does not stop the flow of airborne water droplets through the floor ducts, it will be necessary to remove the evaporator case from the vehicle and perform the following additional changes.
NOTE:
THE CUSTOMER SHOULD BE INFORMED BEFOREHAND THAT THERE WILL BE A NOTICEABLE DIFFERENCE IN THE TEMPERATURE OF THE AIR BEING DISCHARGED THROUGH THE INSTRUMENT PANEL REGISTERS LOCATED ON THE DRIVER'S SIDE OF THE VEHICLE VERSUS THOSE LOCATED ON THE PASSENGER'S SIDE. THIS TEMPERATURE DIFFERENCE COULD BE AS HIGH AS 20~ F.
1. Remove three (3) screws and pull the air inlet duct away from the evaporator case.
2. With a small saw, cut the top of the evaporator case between the dotted lines, Figure 2.
3. Remove the evaporator core from the case.
4. Cut the temperature door frame off as shown in Figure 3.
NOTE:
THIS CAN BE DONE BY USING A CUTOFF WHEEL OR HACKSAW BLADE.
5. Install two (2) pieces of 3/4"(19.05mm) x 3/4"(19.05mm) x 3"(76.2mm) stiff foam rubber (locally procured) inside the case in the locations shown in Figure 4. The purpose of these pieces is to shift the evaporator core as far as possible toward the passenger side of the vehicle.
6. Obtain a service cover (E9SZ-19B735-A) and hold it tightly against the case. Drill five (5) 3/16" (4.763mm) diameter attaching holes for the cover.
7. Install the evaporator core in the case.
8. Install the service cover using the five attaching screws provided in the service cover kit (E9SZ-19B735-A). Be sure to seal all holes in the case. Use caulking cord rope sealer (D6AZ- 19560-A).
9. Drill three (3) 1/4" (6.35mm) drain holes at the bottom edge of the small vertical wall in the evaporator case as shown in Figure 4. These holes will allow any water accumulation to drain back into the heater core area.
CAUTION:
DRILL THROUGH THE WALL, BUT DO NOT DRILL THROUGH THE BOTTOM OF THE EVAPORATOR CASE.
10. Install the evaporator case.
11. Test drive the vehicle. Include several right and hard left turns in the test to force any condensate which may have accumulated in the case to flow out through the floor ducts.
PART NUMBER PART NAME CLASS
D6AZ-19560-A Caulking Rope AG
E9SZ- 19B735-A Service Cover Kit C
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 92-3-1
WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 And 1993 Models, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
921208A Evaporator Case Rework 1.0 Hr.
921208B Evaporator Case Follow-up 4.5 Hrs.
Rework (includes Evacuate, Recharge And Freon R-12 Recovery)
DEALER CODING BASIC PART NO. CONDITION CODE
19850 08
OASIS CODES: 208000, 208300, 208999