T & C condensate (water) in cabin

My 2002 T&C EX has begun dripping water from the cabin air filter housing, but only at start-up. I pulled the filter and it is a mangled, dripping mess -- obviously useless. Which brings me to 2 questions:

1. What is at work here? Why is water accumulating and soaking the filter?
------------ and -------------
2. Should I even replace the filter?*

* I searched these forums via Cabin Filter and found that some feel it is a waste of $$$ and simply "another maintenance item" that we got along without for decades.
There was one poster that said in some (Japanese) cars the filter prevents "dust & pollen" from clinging to the wet evaporator and (eventually) corroding it (pinholes).

I will appreciate some guidance regarding # 1 and 2. Thanks!
- h52

Mine doesn't have a cabin filter though I wish it did. I like the thought of not breathing in at least some of the crap my car travels through.

Check your wiper well drains. Should see about a 1 inch diameter flextube connected in the area above/behind the alternator. Matching tube on the drivers side. Disconnect and pull the crud out. Keep the tubes disconnected and pour water into the vent intake in front of the windshield. Make sure the water drains out the disconnected tubes. Reconnect the tubes and you're done.

RIP, thank you very much for your reply.

I did as you suggested and poured a small amount of water into the middle of the vent area; it immediately ran out of both tubes. (BTW, there is no tube on the pax side, just the opening from the wiper pan). So it looks like that is not the cause.

Does the A/C evaporator have a drip pan? I'm guessing the drain tube from the pan may be partially clogged. That was my first reaction, but I can't locate the tube because I can't slide under the van!

- h52

Here's a TSB on the subject: http://en.allexperts.com/q/Dodge-Repair-809/2008/4/Drain-hole-plug-C.htm

Will try to find a picture to zero in on the location

Thanks again, RIP. A picture or sketch would sure be helpful. I myself have Googled it before I even started posting, but no luck. I hope you can find one.

- h52

Second picture in the second post is the best one I can find :http://forum.chryslerminivan.net/showthread.php/6273-AC-leaks-water-on-driver-s-side-floor?highlight=water%20drip Click on it to blow it up. Looks like its behind/below the alternator just to the right of the surpentine belt. You may find you just have a 1 inch tube sticking out. There is a kit to mod it with the 90 deg elbow at NAPA:http://forum.chryslerminivan.net/showthread.php/15223-Evaporator-Drain-Tube-Fix

Of course now that I look at the pics, they are for a 3rd generation 2000. You have a 4th gen van. Hope they are the same in respect to the drain.

You're a lifesaver, RIP. Thanks for investing the time to help me -- and no doubt, others, as this seems to be a fairly common problem. I'll get on it tomorrow and report back on the result.

- h52

I found the drain tube. In my van (2002) it is a (plastic?) tube about 2 inches long, which juts straight out from the firewall (unlike the banana-shaped tube in the pic).

I cannot reach it from the hood, even with the air cleaner cover removed, and it cannot be accessed from beneath unless the van is lifted off the ground. From the front of the car with the hood open, I used a 28 inch plastic curtain rod to poke into the tube, but it went in only a short distance before it hit a "solid" obstacle, which I am guessing is a screen molded into the drain tube.

In my case, water drips from the cabin filter case, NOT from the firewall, so it is likely the condensate is accumulating in the evaporator drip pan as a result of a clogged drain tube. I will have to get the van on a lift; if the 2-inch tube can be pulled out, it should be a simple matter to clean. Hopefully that will end this matter.

- h52

call your dealer and give them vin to check for recall, most of the 4th generations have the recall cause it can cause a fire, both of ours did...the waters not draining right which causes condensation to build up in vents allowing water to drip on radio, they replace tube and install something in vent area. all free.

a filter will help keep the metal fins clean, and help with smelly air on recycle as rip mentioned...

Thanks for the info, Cntrysthbst; I will absolutely do that.

In the meantime, here is an update for any who are following this thread.

I consulted my mechanic who informed me that the only way to access the interior (evaporator & drain pan) is to pull the entire "dash", which I already knew. In lieu of that, he uses high-pressure air to blow any accumulated crud away from the drain tube and allow the water to drain. The disadvantage of that approach is eventually the crud will migrate back to the drain tube and you'll have to apply the high-pressure air again. But it certainly beats pulling the "dash"!!!

So I went home and using a 24-inch metal extension (Harbor Freight item 34226) for my air gun, stuck the tip into the 2-inch tube protruding from the firewall and gave it a few blasts.

The weather here in So.Florida has not been the usual sauna, so I'll have to wait to see if the "fix" was effective, but so far, so good. :)

- H52