Well i just happened to stick my hand under my carpet on my passenger side a few weeks ago and it was wet. So out came the interior. Its been annoying driving around with no carpet for the last two weeks.

anyways ive tracked the leak to the condensation drain line behind the glove box and goes out into the firewall.

04-06 has a TSB out for it, and i think i will follow those procedures to fix mine.

here are some threads i found after searching for 30 minutes
https://www.f150online.com/forums/sh...ht=leak+inside
https://www.f150online.com/forums/sh...highlight=leak
https://www.f150online.com/forums/sh...highlight=leak

more pics and information as it progresses.....

 

Have you checked for the simplest item - a clogged condensate drain?

Very common...

Steve

 

I stuck over a foot of 8g wire into it with zero resistance so its definetly not clogged.

I spent over an hour cussing that rubber elbow. It just didnt want to go on there. I called it a night because my hands hurt so bad....

There was a plastic cover over the drain that looked like it diverts the water away from the starter, and may also block some incoming air. I had to remove it, and probably will leave it off if i can get this damn 90* elbow to go on it.

 

i had this on my truck and many others with 2003's have had this issue because ford changed the firewall in 03 (alteast thats what i read somewhere)

 

Just finished doing the same thing to my 04. That elbow is a mother to put on. I used the dielectric grease as per the TSB, but it wouldn't go on. I put a small socket inside short end to stretch and put it in some boiling water for a couple minutes to soften it up. It finally went on.

P.S. Thanks Ford for putting a crappy drain in the most unfriendly of places.

 

yah i talked to my friend about it he said dont use the grease it doesnt help, just makes the elbow slippery to go back on.

heres how much water i was leaking inside

 

patman where are you getting full tsb write ups like in your picture?

I found the one you have by googling the tsb number, but I want to see all of them.
http://fcsdchemicalsandlubricants.co.../tsb/07135.pdf

 

Alright, If the firewall pad looks wet, then most likely your ac condensation line is leaking. Run the truck and feel around the foam padding that surrounds the line. The bottom padding should be moist feeling.

Moist firewall pad.



You can see where it drips down to the bolt, then slides down into the passenger rocker. Perfect setup for rust.



After you fix the leak, be sure to wipe all the stainage down, so it doesn't start more rust.

 

I get the TSBs from my local dealership since i have a few friends that work there.

 

Just completed TSB work. I boiled the elbow for a minute and it went on without a hitch. Figured I would let the next person know, since I spent a half hour trying to fight it on at first. A few choice words flying around during this one.

TSB 06-8-15 is another one I did today. IWE Solenoid part # 6L3Z-9E441-A. If you havn't looked into this one, I highly recommend doing a search on it.

Nothing like preventative maintenance based on TSB's...