soaked passenger carpet

97 JGC, passenger side carpet soaked from evaporator condensate. small 1/4 inch hole already drilled in air plenum, doesn't seem clogged up. water is coming in from around the plastic part at the bottom. there is no drain hose on this model. jeep dealer says dash has to be removed. anyone know of another way to stop the leaking?

Here's the TSB on this problem: http://home.sc.rr.com/janet/TSB/24-06-96.htm

legalfee, thanks for the TSB, however, this hole had been drilled and sealed before i took possession of the jeep. the water is leaking in below the dark round part of the plenum. i have taken a wire and poked around in the hole, but no debris comes out. you can see the water come in while the ac is running. a local shop told me that the water is running back down a drain tube and into the interior. it doesn't mean that the tube is stopped up. jeep dealer wants 8 hours to pull dash and look at the problem.

when your a/c is turned on the water leakes out of the bottom of the jeep, well jeep put the drain tube right in front of the passanger seat and thats usually the problem because it leakes out to a part of the body and water can collect then the carpet will get wet because it has nowere to go (in most models) some newer jeeps have holes in the body (its hard to understand, i had to have someone show it to me) but thats were i just got the idea to drill my own holes. and thats what solved the problem with my jeep.

thanks for the replys. here is what i finally did. i took some 'dum-dum sealant' and just stuck it around the plenum box inside the jeep where it went toward the outside. hopefully this will work until i sell it or trade it in.

I just wanted to say thank you for everyone that posted the solution here. I indeed did the drilling order the plug and it was still leaking. I figured out that it was coming from under the plastic piece going into the firewall. I used some clear silicone sealent to fix that portion.

I also had to take up my carpet to let the floor board area dry out. To do this I took out the seats and it dried in the Texas heat. I now have puddles under the Jeep, where they should be to start with.

If anyone needs the directions on how to correct this, then let me know by emailing me at [email protected]. I took pictures to help the non mechanic types out.:smokin:

I too just did a repair like this. I unscrewed my antenna and drilled the hole in the condensate and then used the antenae to ream out the hole. No debris came out but I had a cup under there for a few hours as the liquid leaked out. I pulled back all the carpets cleaned it all up, dried it. Then I used a super flexible RTV sealant flexible from -232 to 232 degrees as the sealer around the underneath (round part of the evaporator consendate). I had to peel away some of the old black gasket above and below the drill hole and used the sealer there as well. After overnight curing of the silicone it was perfect not a drop thereafter. There is a video on utube if you type in jeep a/c repair, with the procedure i mentioned above.