Water Leak Due to HVAC Case Not Sealed at Bulkhead on Dodge 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: 101,666 (95,000–110,000)
7 model years affected: 2000, 2001, 2002, 2003, more2004, 2005, 2006
14 people reported this problem
Viewing 1 - 5 of 5 comments
Water on floorboard of passenger side noted. Pulled trim and carpet to find puddles and soaked mats. Cleaned evaporator tube for HVAC which may have staved water flow some when A/C running but otherwise, still leaks in some. Plan to put silicone or this "foam sealent" around tube at exterior and as best as one can on interior then add a L shaped tube to the evaporator tube to divert flow groundward rather than allow it to flow back to firewall (bulkhead).
Water is leaking under the rug on the passenger side of the van. Have not been able to have it fixed yet. Hoping it was a recall so I wouldn't have to come up with the money to pay for it.