Water leak in passenger foot well from AC heaterbox, drain plug is clear

[okyoureabeast]

Hey guys,

I'm troubleshooting a small leak that is coming from the AC box inside the dash.

Expecting to find clogged drain plugs, I pulled away the carpeting and got a closer look.

For good measure, I took a thin strip of bamboo and made sure the drain pipe was clear. I also stuck the bamboo into the black box that houses the AC condenser to make sure it was clear.

I confirmed that water drains a lot more easily through the drain pipe. However, I still have a few small droplets coming from this part of the plastic housing:



If you look closely you can see the water starting to bead up.

Water does in fact come out of the drain hole, but i'm worried there might be a hairline crack on the housing that I can't see.

What are my options? Would it be worth it to try and plastic JB Weld the area or get some sort of big funnel to try and catch the water as it falls into the drain?

Any advice would be appreciated. Thank you!

[Diseasel300]

I'd suspect a crack there as well. Certainly worth using some RTV or something to try to patch it.

Not automotive related, but we had this same issue in the drain pan with the A/C in the office at work. Would randomly drip below the unit and never could find it. Wasn't coming from the coil and we couldn't find any other source. Eventually had the pan replaced and it had a microscopic crack at an injection mold line. Too small to see, but big enough for water to bead up and drip through...

[okyoureabeast]

Grr, tried my patch and it's still leaking albeit a lot more slowly this time.

I think my next best option will be to rig up some sort of funnel that catch the drips and send it to the drain hole. Time to search Google.