Water Leak Due to HVAC Case Not Sealed at Bulkhead on Dodge Dakota

If the HVAC (heater) housing is not properly sealed at the bulkhead (firewall), water can leak into the passenger compartment. Foam sealant should be used to seal any gaps and the evaporator drain tube can be modified to prevent further water entry.

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Average mileage: 99,869 (44,000–150,000)
6 model years affected: 1996, 2001, 2002, 2003, more2004, 2006
20 people reported this problem
7 people shared problem details
wet passenger floorboard
passenger side floor/carpet is always wet. changed windshield twice,resealed it twice. now I notice bottom of heater box inside has a water stain,not sure if its my a/c or a leak
2002 Dodge Dakota44,000
Followed the guide lines from the Service Bulletin Number 23-010-04 dated April 29th, 2004
leak on passenger side
2003 Dodge Dakota101,000
Passenger side floor soaked.
1996 Dodge Dakota150,000
sounds like the problem i have. Took it to a shop, had them replace heater core hoses, clamps, and heater core. 3 months later, it is leaking again. Also, they could not get my defrost to function properly and was issued a refund.
problem started at about 50,000. dealership wanted $700 to repair the seal.
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