Air Conditioning - Water Drips On Floor
Article No.95-23-3
11/20/95
AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE
FORD:
1989-95 THUNDERBIRD
LINCOLN-MERCURY:
1989-95 COUGAR
LIGHT TRUCK:
1995-96 EXPLORER, RANGER
ISSUE:
Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned.
ACTION:
For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the Thunderbird/Cougar Service Procedure.
SERVICE PROCEDURE
RANGER/EXPLORER
1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck.
2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual.
3. Remove the service cover on the evaporator case.
4. Remove the evaporator core.
5. Inspect the foam evaporator strip seals for proper positioning (Figure 1).
6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly.
7. Verify the repair.
DIAGNOSTIC TIPS
THUNDERBIRD/COUGAR
The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible:
1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern.
2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following places (refer to Figure 2):
a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time.
b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage. This seam may not be adequately welded during assembly. When this occurs, condensate may leak from the case in this area. The seam is not visible when the evaporator is assembled in the vehicle. It is difficult to determine between leaks from this source, or source a, above. Generally, leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber.
c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger 5 feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes.
3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate.
a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued.
b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns.
SERVICE PROCEDURE
THUNDERBIRD/COUGAR
1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12.
2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows:
a. Remove the evaporator case from the vehicle as outlined in the appropriate Service Manual, Section 12.
b. Remove the evaporator tube seal from the case (Figure 3).
c. Cut away the portion of the liquid line clip that extends outside of the case.
d. Apply a generous bead of RTV sealant to the inside of the case as shown in Figure 3.
e. Apply a generous bead of RTV to the evaporator tube seal as shown in Figure 4.
f. Reinstall the evaporator tube seal being careful to ensure the RTV seals around the entire perimeter of the seal.
g. Apply a bead of RTV around the perimeter of the seal where it meets the case.
h. Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case.
3. Diagnosis # 2c. Heater core cover seal.
a. Remove the heater core cover and seal.
b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV.
c. Apply a bead of RTV to the heater core cover along the inside face as indicated in Figure 5.
d. Reinstall heater core cover seal and heater core cover.
e. Apply a bead of RTV between the heater core cover and the case.
4. Diagnosis # 3a. Loose lower mounting stud.
a. Tighten nut as required.
5. Diagnosis # 3b. Water in passenger side kick panel.
a. Follow the Service Procedures listed in TSB 94-22-5.
OTHER APPLICABLE ARTICLES:
94-2-12, 94-22-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Base Warranty Coverage For All Others
OPERATION DESCRIPTION TIME
952303A Stretch And Reposition 2.5 Hrs.
Evaporator Core Seals -
1995-96 Ranger/Explorer
952303B Condensate Carryover - Refer
1989-95 To TSB
Thunderbird/Cougar 94-2-12
952303C Evaporator Tube Seal And 2.7 Hrs.
Leaky Seam Repair -
1989-95
Thunderbird/Cougar
952303D Heater Core Cover Seal 2.2 Hrs.
Repair - 1989-95
Thunderbird/Cougar
952303E Lower Mounting Stud 0.2 Hr.
Retighten - 1989-95
Thunderbird/Cougar
952303F Water In Passenger Side Refer
Kick Panel Repair - To TSB
1989-95 Thunderbird/Cougar 94-22-5
DEALER CODING
CONDITION
BASIC PART NO. CODE
19850 36
OASIS CODES: 110000, 208000, 208300, 208400, 208999