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

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: 126,553 (50,000–240,000)
5 model years affected: 2001, 2002, 2003, 2004, more2005
29 people reported this problem
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problem details
2002 Dodge Grand Caravan 98,000 mi,
vehicle is leaking from underneath the passenger side of my 2002 chrysler van. the front passenger floor is always wet.
2003 Dodge Grand Caravan 50,000 mi,
any time we use the air conditioner, water leaks onto the floor of the passenger side. carpet is always soaked!
2005 Dodge Grand Caravan 154,000 mi,
HVAC leaks on the passenger side carpet.
2001 Dodge Grand Caravan 118,000 mi,
when air conditioner on in summer the passenger side rug and carpet get soaked and has a white residue.
2002 Dodge Grand Caravan 135,000 mi,
It is wet on the floor board of the passager side
2002 Dodge Grand Caravan 145,000 mi,
It is not fixed
water in the passenger side
2003 Dodge Grand Caravan 85,000 mi,
Leaks in heavy rain
2001 Dodge Grand Caravan 138,000 mi,
Front passanger side carpeting is always wet.
When the A/C is on there is a leak from the firewall area. My guess is a misalignment of heater core as my dashboard once had to be removed to track down an electrical issue. This problem has not been fixed.