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

Problem Description and Possible Solution

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.

Problem Data
RepairPal Verified
Average mileage: 127,225 (50,000–240,000)
5 model years affected: 2001, 2002, 2003, 2004, more2005
30 people reported this problem
Viewing 1 - 11 of 11 comments
vehicle is leaking from underneath the passenger side of my 2002 chrysler van. the front passenger floor is always wet.
any time we use the air conditioner, water leaks onto the floor of the passenger side. carpet is always soaked!
HVAC leaks on the passenger side carpet.
when air conditioner on in summer the passenger side rug and carpet get soaked and has a white residue.
Water on front passenger side floor.
It is wet on the floor board of the passager side
It is not fixed
water in the passenger side
Leaks in heavy rain
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.