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Old 08-05-2012, 01:30 PM   #2
TheyDontWantMus
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Join Date: Dec 2011
Posts: 484
Default Re: Water water everywhere? Another leaking ford?

I believe this is happening..

the passenger side air vent, that ducts from the plenum chamber into the cabin passes through two layers of metal, the plenum chamber, and the firewall.

it has a foam seal on a flange on the inside of the cabin, which is meant to seal to the firewall. it also has a "hood" in the plenum to stop water running into the vent.

problem is, the hood catches and directs water back towards the firewall, where it then runs around the plastic duct, into the hole, and down between the two layers of metal (the firewall and plenum chamber) and into the cabin.

it appears that to remove the duct and seal it properly, will require me to remove the entire dash board...

I guess it is a 23 year old car, but it would have been nice if they could have used sealant to begin with, instead of a foam gasket thats basically non existent now.
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