Posted several times before, always been an issue around my aircon drain but seems so unique to just my car. Suffered with this for 3 years. 
 

Problem seems to be a badly blocking aircon drain. Although I cannot find any blockage.

Once a year or so I get this issue.

symptoms are condensation dripping into both foot wells, hvac seems to be flooded so even with the AC off the fans blow water out the side of the pollen filter box into drivers footwell. Smell is unbearable and everything is damp.

What really is the solution? Garage want to take the dash out. 

thanks

 

Yeah, I'd be taking the dash out too, unfortunately

Removing the dash to see if there's something stuck in the HVAC box under the AC evaporator would be the only real solution.

Is there any sort of valve in the drain pipe on these or is it just a straight pipe from the box to the chassis?

Is the pipe kinked at all?

4 hours ago, connorp0601 said:

What really is the solution? Garage want to take the dash out. 

With out removing the dashboard, I don't see that there can be any other way of solving this problem.

23 hours ago, TomsFocus said:

Removing the dash to see if there's something stuck in the HVAC box under the AC evaporator would be the only real solution.

Is there any sort of valve in the drain pipe on these or is it just a straight pipe from the box to the chassis?

Is the pipe kinked at all?

It's less of a pipe and more of a gully which goes from the bottom of the unit to an exit above the exhaust heat shield, not sure if there is a valve etc, the garage have on many times cleared the gully etc, but never been able to get rid of the blockage that possibly exists further up in the system as you suggest. 

Unfortunately the system is so flooded I can't even use the fans without AC to dry out the car water just bubbles up into the pollen filter compartment then seeps out the sides, smells horrendous!   

You could try removing the dash lower panels, centre console, seats and carpet first to see if the fault lies between the HVAC and the body at the bottom.

Just checked and see what you mean now.  No pipe, just straight into the chassis from a 'prong' on the bottom. 

It's surrounded by foam, so maybe the foam got snagged during fitting and has partially blocked the hole.  

I can't see any sort of valve externally.  On much older cars I have seen a weight activated valve that's meant to open when there's enough water on top but they don't always work.  Easy enough just to wedge them open permanently though.

Really, the only other thing I can think of is that there's something stuck in the bottom of the HVAC box.  Possibly packaging from manufacture, or possibly leaves that dropped the wrong side of the pollen filter when it was removed.

Sadly, I can't see any solution that doesn't involve removing the dash & HVAC box.  

This image is upside down, so the drain is on top here.

(Watch your shoes!  )

 

2 hours ago, DaveT70 said:

You could try removing the dash lower panels, centre console, seats and carpet first to see if the fault lies between the HVAC and the body at the bottom.

Yeah that’s right. Done that on and off for years. It’s always damp around the foam part in Toms Photo. Often plenty of condensation on the back of that gridded part with water seeping out both sides. 
 

it’s absolutely got to be a blockage within the system. Which will need taking out I think. 

2 hours ago, TomsFocus said:

Just checked and see what you mean now.  No pipe, just straight into the chassis from a 'prong' on the bottom. 

It's surrounded by foam, so maybe the foam got snagged during fitting and has partially blocked the hole.  

I can't see any sort of valve externally.  On much older cars I have seen a weight activated valve that's meant to open when there's enough water on top but they don't always work.  Easy enough just to wedge them open permanently though.

Really, the only other thing I can think of is that there's something stuck in the bottom of the HVAC box.  Possibly packaging from manufacture, or possibly leaves that dropped the wrong side of the pollen filter when it was removed.

Sadly, I can't see any solution that doesn't involve removing the dash & HVAC box.  

This image is upside down, so the drain is on top here.

(Watch your shoes!  )

 

These photos are fantastic! Yes that’s right as you can see no way at all to reach the bottom of the drain without it coming out. I’m confident the bottom half of the HVAC behind the pollen filter compartment is flooded. The blockage must be in and around that foam area either just below or above within the system itself. 

This is the area they’ve not been able to access with “traditional” air con drain clearing techniques.

Theres often lots of condensation just above that drain on the inner facing side (the bumpy section) this is usually the first tell tale sign of it blocking in the past. Just this time they can’t solve it. 

The foamy part is also very damp with water seeping out when squeezed. 

I’ve never seen another issue resembling mine with any other Fords using that HVAC either! Gonna have to wait and see what the blockage could be. I do have extended warranty however I’m not sure it may be of use if the blockage could be seen as ware and tear! 

Definitely going to be a dash out job then. 

 

May be going off on a tangent but is everyone convinced there is an actual blockage?

Looking at the photos of that contraption I would surmise that water could collect in a number of places and move when the fan is running. From the conversation so far it seems to me that there is more water about than would be produced just by 'condensation'.

Could excess rain/jet wash/auto wash water be getting in somehow? I assume there is never any loss of coolant.

1 hour ago, RayC333 said:

May be going off on a tangent but is everyone convinced there is an actual blockage?

Looking at the photos of that contraption I would surmise that water could collect in a number of places and move when the fan is running. From the conversation so far it seems to me that there is more water about than would be produced just by 'condensation'.

Could excess rain/jet wash/auto wash water be getting in somehow? I assume there is never any loss of coolant.

Never any loss of coolant, liquid doesn’t smell sweet either like coolant. 
 

Issues been on going for years. Always caused by the aircon drain being blocked and no aircon pooling under the car. In the past the garage have been able to free up what they say is “part of the blockage” but never been able to fully sort it as it will always return 10 or so months later. Same symptoms same cold condensation and so on. Obviously the symptoms don’t rear their head until it’s too late and is leaking into the carpet/misting up of the windows.

This time however they’ve not been able to remove any blockage and have suggested the dash out which over the last few years I’ve been reluctant to do. But it will be the only way to diagnose the unit as broken or blocked and ultimately solve it/get a warranty claim!

I’ve always ran the aircon as well so it certainly gets its use and it doesn’t help I live in an area with generally high humidity either!

 

Let them take the dash out👍