A/C Evaporator - Condensate Leaks
Article No.92-20-3
09/23/92
AIR CONDITIONING - CONDENSATE LEAKS FROM EVAPORATOR CASE INTO PASSENGER COMPARTMENT - VEHICLES WITH MANUAL OR ELECTRONIC A/C BUILT THROUGH 6/11/91
FORD:
1989-91 PROBE
This TSB article is being republished in its entirety to revise the Core Tube Seal part number.
ISSUE:
Condensate may leak from the A/C evaporator case into the passenger compartment. The leakage is primarily on the passenger side directly onto the carpet. This usually occurs because...
^ The evaporator drain tube is not open or draining properly.
^ The airborne moisture is not directed properly toward the evaporator outlet drain tube.
^ The A/C system controls are not operating in the recirculated air position.
ACTION:
Inspect the vehicle for water condensation leakage. Refer to TSB 89-16-7 to confirm the length and position of the evaporator case drain tube through the cowl panel. Also refer to TSB 91-8-6 for cowl water leaks that could cause leakage through the A/C case onto the passenger side carpet. Install a metal air baffle (F12Z-18A384-A) between the blower motor housing and the evaporator case, Refer to the following procedure for service details.
NOTE:
THIS TSB SHOULD BE PERFORMED BEFORE DOING THE REPAIRS COVERED IN TSB 92-2-5.
1. Remove the passenger side lower instrument panel trim cover and the glove compartment assembly to allow visual access to the A/C evaporator case.
2. Check the evaporator drain tube for restriction.
a. Remove the A/C rubber drain tube from the evaporator case.
b. Insert a small lead pencil (eraser end) about 3 to 4" (76-102 mm) into the evaporator case.
^ If tube is not restricted, proceed to Step 3.
^ If the tube is restricted, remove the evaporator housing and inspect/repair as needed.
3. Inspect for the correct position of the A/C drain tube grommet through the cowl. This can be seen from inside the vehicle, Figure 1. If the grommet is missing, damaged or mispositioned, refer to the parts block of this article for the replacement part number.
4. Inspect the A/C evaporator core tube seal, Figure 2.
a. Perform the inspection from the engine compartment by looking between the charcoal canister and the cowl.
b. Use a light to observe the seal at the inlet/outlet tubes of the evaporator core.
c. If it is missing, refer to the parts block of this TSB article. Replace it if damaged or reposition as needed.
5. Refer to Figure 3 for the installation location of the special air baffle (F12Z-18A384-A).
6. Unhook the evaporator to blower motor housing air duct band and slide it out from the two housings. This will expose the slot opening where the baffle will be installed.
7. Install the baffle by sliding it into the gap between the two housings. The baffle tab must rest flat and be toward the blower motor housing.
a. Align the hole in the baffle with the metal retainer clip in the blower motor housing.
NOTE:
THE METAL RETAINER CLIP IS ONLY USED ON MANUAL A/C. IF A PROBE WITH ELECTRONIC A/C IS INVOLVED, INSTALL A METAL RETAINER CLIP (E92Z-14A163-D) IN THE BLOWER MOTOR HOUSING. THEN, INSTALL THE BAFFLE TO THE BLOWER MOTOR HOUSING.
b. Insert a plastic push pin (F1CZ-5831172-B) through the baffle and retainer clip to secure it to the blower motor housing, Figure 3.
8. Install the air duct band, making sure it covers and secures the tab of the baffle. This will prevent the baffle from rotating or moving out of position.
9. Activate the A/C system.
a. Start the engine.
b. Depress the A/C button.
c. Place the air control in the "FRESH" position.
d. Turn the blower to the Number 1 position.
e. Leave the vehicle doors open.
f. Allow the engine to run for about 10 minutes.
10. After about 10 minutes, proceed as follows:
a. Turn the blower motor to the highest position.
NOTE:
IF THE AIR CONTROL CABLE "WALKS" OR MOVES FROM FRESH TO RECIRCULATE (FROM RIGHT TO LEFT), REFER TO TSB 91-17-3 FOR THE CABLE ADJUSTMENT PROCEDURES.
b. Inspect for moisture leaking or dripping from the blower motor housing to the evaporator housing joint and/or from the evaporator to heater housing joint.
c. If no leakage is observed, reassemble the glove compartment and trim panel. Return the vehicle to the owner.
11. If moisture leakage was observed when the blower was turned to the highest position, proceed as follows:
a. Remove the air duct band.
b. Add a piece of duct tape, 6-7, (152-178 mm) long to the lower joint(s) that were leaking, Figure 4.
c. Reinstall the air duct band.
12. Install the glove compartment and lower trim panel.
NOTE:
THE "RECIRCULATION" POSITION USES INTERIOR AIR THAT IS DRIER (LESS HUMID) THAN OUTSIDE AIR AND WILL REDUCE MOISTURE/WATER CONDENSATION BUILD UP INSIDE AND OUTSIDE OF THE BLOWER MOTOR, EVAPORATOR HOUSINGS. THIS WILL REDUCE CONDENSATION ESPECIALLY IN HIGH HUMIDITY CONDITIONS
OTHER APPLICABLE ARTICLES:
89-16-7, 91-17-3, 91-8-6, 92-2-5
SUPERSEDES:
92-4-5
WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
922003A Install Metal Air Baffle. 0.5 Hr.
922003B Repair Drain Tube Blockage 0.4 Hr.
In Vehicle.
922003C Remove Evaporator, Case 2.7 Hr.
And Repair Drain Tube Hole
Or Replace A/C Evaporator
Core Tube Seal.
DEALER CODING
BASIC PART NO. CONDITION CODE
19858 55
OASIS CODES:
208000, 208999