Engine/Transmission (1994 - 1998) A/C water leak in cab

[JRS]

replaced A/C evaporator core yesterday. job was OK, got the system charged and noticed water running out the defrost ducts onto the floor. (it was also running out the tube on the firewall like it should be) I was extra careful when I split open the HVAC box, I glued all the foam on the new core exactly where it was on the old core except across the top. the existing foam on the top of the old core was in bad shape and couldn't be re-used. In addition, there was a paper thin piece of white foam that couldn't be used either. it looks like it was a mistake not to put something back in to replace both of these. I have tried vaccuuming out the tube on the firewall, the only thing that came out was water. (the whole inside of the case was hospital clean when I put it back together) Any ideas?



FYI- the old evap core was a mess! (so was the inside of the box) there was some kind of funk growing in there, but a quick wipe down with clorox and water got it all out... .

 

[Missouri Mule]

jrs,

I believe there are two drains but one hose I 'll have to look in manual.



The foam is for insullation purposes only not sealant for coolant/water.



Since there is a temp door they insulate heater/evaporator core so cold doesn't mix with hot when you want cold and vice versa.

My ford van was like this.

 

[JRS]

you have the same reply my buddy the mechanic did. the foam is for mounting and insulation only, not seeling. I don't think I messed up the placement of the doors, since the air blows from all the right places when you use the selector switch, but I could be wrong. I spoke with a Dodge mechanic yesterday and he said he never replaces the thin white foam tray when he does a evap changeout at the dealership, he just leaves them out. The parts people were nice enough to pull a new evap off the shelf and check in the box. sure enough, Dodge doesn't give you a new foam tray either.

 

[JRS]

I made it all the way to work with the A/C blowing full blast, and it didn't produce a drop of water in the heater ducts or on the floorboard. I did notice that I have a small amount of air coming out the heater ducts with the A/C selector in the "panel" or "recirc" position. is this normal? (I have owned this truck for six years and can't believe I am asking this question) when I move the selector switch to "panel/feet" position, the air at the floorboard picks up substantially in volume.