Help please!


Vehicle - 2003 Ford Expedition XLT, 5.4 liter engine, 4x4, with rear AC/Heater.


Problems

1. Smell of anti-freeze coming with heater when it is on.

2. Pint of CLEAR clear water (condensate) in front passenger floorboard (not anti-freeze coolant). Water was in right electrical tray that runs next to right front passenger door. Bad place for it.

3. Only the horizontal carpet on the passenger floor was wet, including the insulation. Soaked! The slightly vertical carpet and insulation coming from the firewall was dry as well as the carpet and insulation around the middle console and chair.


Actions Taken

1. Removed entire dash and steering wheel column (had to remove dash).

2. Removed front seats and floor duct that goes under seats.

3. Evacuated air conditioner.

4. Removed air plenum.

That was a job that took more than 14 hours. The spring connectors from the AC block going to the AC evaporator was difficult (even with the spring tool) to take off as well as the 11 mm nuts holding on the air plenum.

There was no physical method to replace the heater core unless you removed the entire air plenum.


Additional Tests and Results

1. Performed radiator leakage test. Prior to starting job, determined that the radiator (16 lb) leaks at the rate of 1 pound every 20 seconds.

2. After removal poured colored water into firewall condensate hole to ensure AC condensate line was free. Line was clear and flows well out the vehicle onto the ground.

3. Checked the AC Evaporator air plenum drainage area to ensure no leaks in it. No leaks.


Questions

1. What is the source of the clear liquid going onto the passenger floorboard? Could it just be cold air meeting hot air?

2. Is there WEB site to purchase a tape like flexible floor to put to horizontal floor on to seal it up?

3. Would you recommend replacing the AC evaporator and entire air plenum (everything including plenum door solenoids) while I am there? I do not want to repeat this again. The 2003 is different than the 2002 and prior models. The air plenum door is built into the entire air plenum.

4. What is the best WEB site to purchase the air plenum at a good price? The air plenum is a Ford part, correct? I cannot find the plenum in the aftermarket.

5. Is this a good WEB site to purchase parts (http://wholesale-ford-parts.com/)?

6 How do you do a vinegar radiator flush? This is what the Ford dealer recommended.

7. Comments and suggestions are welcomed.


Side comment

Have taken close to 200 photos of the entire process so far. Can I post them on the site as an aide for someone in the future?

Two Ford dealers estimated this to cost at least $1200.

Searched this WEB site and find any thread like this issue.

Thanks for your assistance.

 

If u smell anti-freeze, I'd say u definitely have a coolant leak somewhere. But in reguards to the water, does it show up after a rain or when u wash it? Does it have the third brake light? I had a similar problem; right front floorboard getting soaked. Took it to an indepentent guy that specialized in water leaks. He had it twice and couldn't find it. It turned out to be a bad seal around the third brake light. It was running all the way around this internal lip and running down the a pilar on pass side. Simple fix.

 

The condensation from cooling the air runs out a drain line to the ground under the vehicle. Crawl under, and locate the rubber drain hose, run a wire up the drain line to unplug it and maybe it will drain properly.