My 2003 is dry, could use some help on where this drain is suppose to be on the firewall. Assume it is behind the AC unit?

 

Today I lodged my complaints about this probelm with the Ford Customer Relations Center at 800-392-3673. While they were of little help regarding what the future holds, they did say that calls from owners highlighting these sorts of issues are what drives the recall / service letter / modification activities. As such, I encourage all owners who have had this probelm to call them and go on record with your VIN. This ensures that any future Ford initiative will make its way through to you.

If we don't, then be certain that the truck will outlive your synthetic carpeting.... and the musty odor may well outlive your ability to stand it.

Regretfully,

Zderf

 

Drain Location:

If you look under the dash on the passenger's side just above the carpet towards the fan vents you will see a square piece of plastic. This covers the drain tube which extends through the firewall. On the outside this tube is covered by a kinda flat piece of black plastic which diverts the water from the O2 sensor to just above the heat shield over the exaust pipe. On my 03 with a 4.6 Triton I can't see a darn thing from topside. I have to crawl underneath look straight up the firewall.


I called FORD today too and complained. Damn what a bitch. But, if theis is the worst I can handle it. At least my doors might not crack...

 

Seems to me that the Plastic would have to get pretty cold to have condensation form on it. maybe adjusting the temp a bit would keep this from becoming a problem. Even just avoiding Max a/c and letting outside air in the box would keep the temp above the condensation level. Otherwise I would suspect that it is not from the outside of the box but the more likely leak from inside the box. The metal of the evap. is much more likely to form condensation( hence the drain line) and if it is indeed too short or if they have a cronic problem with the seams not holding water I would not be suprised. Has anyone felt the exterior of the plenum and felt this condensation? I would really like to know
Thanx

 

Just picked up my '03 Screw from the dealer today. They had it for 10 days to work on this problem!

I took it in when I heard water sloshing around in the passenger side when I accelerated from a stop. It sounded like it was in one of the passenger side doors at first, but swinging the doors open and shut a few times proved that was not the case. I told the service writer that it sounded like it was under the passenger side carpet and that I thought it was from AC condensation because we have had a wet Winter and Spring and I didn't hear the water until recently, after using the AC a lot in the hot, humid weather. Unfortunately I was right.

Turns out that Service Bulletin SSM 16934 pertains to this issue. Per the bulletin (I hope...), they did the following: "Sealed outside drain holes and installed rubber elbow hose. Tested vehicle. Found vehicle still leaking from AC plenum. R & I dashboard and all panels. Removed and resealed AC plenum. Removed all seats from vehicle and removed carpet. Let carpet sit out and dry" (they used a fan). THIS IS THE EXACT TIME I HAPPENED TO WALK INTO THE SHOP DURING MY LUNCH HOUR ONE DAY!!! TALK ABOUT A HEART ATTACK!!! I talked to the mechanic who showed me where the water was trapped. It was in the channels in the sheet metal under the carpet. These are the channels where they run the wiring. So you can guess my next question.....but he told me that I brought it in quick enough that none of the wiring was damaged (time will tell). "Reinstalled carpet and seats. Note: Also evacuated and recharged AC System."

I can't imagine what my dealer charged Ford for this warranty repair. As you can imagine, I went over the truck very thoroughly and it looks like everything was put back together OK. BTW, the AC condensation is flowing like a river onto my driveway now (can't remember seeing it do that before).

 

where can I find this bulletin so I can print it?

 

Brent,

I don't know how or where to access Ford service bulletins. The bulletin number was on the invoice (along with the description that I wrote above).

Maybe someone can give us the link to Ford's service bulletin site?

 

I have an '03 Super Crew and same problem, wet and musty passenger's side carpet. I just left the local dealer and he was aware of the problem, he just did one the other day. He said it was only a matter of putting an extension tube on the drain hose. Not too bad I guess, just the inconvenience of being w/o a truck for a day.

 

Exactly what I found on my '03 Scab. At least on my truck the tube through the firewall is too short and straight. The water just runs back into the cab via the oversized hole surrounded by foam. Does anyone know what this new elbow tube looks like? Hell I can put an extension tube on and a little sealant easier than leaving my truck with the dealer.

 

When I get it back on Friday I'll let you know.

 

This is great info... I just scheduled a visit to my dealership who plans to incorporate this initial bulletin. They indicate that this is the first step towards a final TSB which sometimes lead to a recall. This situation holds promise to be a recall considering the extent of dmage that can result from water being inplaces that it should not be.


More to follow....

Zderf

 

Thanks!

I can't seem to find that Service Bulletin, any idea where I can find it?

 

I had the same problem with my 03. Took it to the dealer and they fixed it no questions asked. Covered under warranty, too. I even got a free forced-variance wheel balance out of the deal

 

Mine got fixed today too. They said I was the second one this week with the same problem. My dealer took the extra step of adding silicone all over the opening too! I don’t know if the leak is fixed but they seemed to have done a good job.

By the way, plan on keeping it there all day, they need the exhaust to cool because the drain pipe is right near there.

 

Anyone get new carpet out of this repair or just a drain tube extension. I still havent brought mine in yet but damn the truck is musty after sitting in the sun all day. Wonder if after the fix I will get rid of the smell without replacing the carpet.