Town & Country

Water Leak Due to HVAC Case Not Sealed at Bulkhead on Chrysler Town & Country

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: 113,111 (40,000–180,000)
5 model years affected: 2001, 2002, 2003, 2004, more2005
16 people reported this problem
Viewing 1 - 6 of 6 comments
Unfixed - already present when we bought vehicle used but has gotten worse to the point the rear carpet and pad between passenger side firewall and the outermost lane for the 3rd row seat hinges has totally rotted out.
There is a seal that goes bad at the location where the condensate drain penetraites the firewall. Once that seal goes bad it allows condensate to blow back up against the firewall and leak inside at this location. The leaking from this problem typically only occurs while the vehicle is being driven. To replace this seal the dash and entire fan housing/heater coil housing has to be removed. It's not worth it. The easy 5 minute fix for this is to buy a short heater hose that is preformed into a 90 degree turn. Slide it on the end of the condensate drain with a hose clamp to hold it in place. Now the condensate will not leak back into the floorboard but down and away like it is suppose to.
Water builds up in the floorboard of the front passaenger seat of the van. Carpet is showing signs of mold. I need to find a way to fix it. One article said to use foam, but where are the directions for this? I want to sell/replace the van, and no one will want a van with a leaky a/c.
Water leaks in around the seal at the firewall. I have not fixed it yet and would like to know how to seal it. The tube or water exit in the engine compartment is open. Input on how to fix it is requested.
water leak onto front passenger side compartment/floor-board when a/c is being used.
I saw the comment advising to use a foam sealant. Do I have to take the dash apart to get to it? Is there possibly a plastic part that may have broken? THANKS for your advice!!