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  # 2048218 3-Jul-2018 12:22
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Dingbatt: The Mondeo I used to own had this exact same problem. When the windscreen was replaced the drain holes that allowed water to drain from the windscreen were blocked. The water overflowed into the airbox that contained pollen filter that in turn led to the airconditioning duct and fan assembly behind the glove box. From there just a short journey the front footwell carpet. Once the water could drain away the problem went away but not long after that the fan started making a noise due to the bearings rusting. Resulted in a replacement fan being required.

 

I also had a 2006 Mondeo that suddenly developed a wet carpet problem on the floor of the back seat area. It turns out that leaves and general detritus (including silver birch seeds) had got past the rubber seal at the base of the side window and into the cavity of the door. This stuff then blocked the drain holes at the base of the door, causing rainwater to overflow inside the door cavity behind the interior door cards, and from there it flowed straight down to the floor area. In this case, the tight rubber door seals that normally stop water getting in actually stopped it getting out during the gravity fed journey from the door to the floor. A renewed side window seal solved the problem.


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  # 2048257 3-Jul-2018 13:11
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I had a similar issue on my Primera and it took me months to figure it out.  In the end it turned out to be leak from a windscreen locator tab that was dropping straight down the scuttle box* (SB) riser into the AC fan.

 

The windscreen had square green plastic locator tabs that were sealed into little holes in the top surface off the scuttle box.  The sealant under one tab had failed and it was admitting water into the scuttle box.  That wouldn't have mattered, except the leak was located straight above the riser and water was dripping down directly into the AC fan. In the end a 10 minute fix.

 

I'd figured out the water was coming in via the AC fan but couldn't see how.  Buying a USB inspection camera enabled me to find the fault.

 

Also: -

 

- SB drains can become blocked with leaves, debris etc.  If they do the SB can fill with water which can then overflow the riser and enter the car (happens); 
- The seal between the SB riser and the base of the SB can fail and admit water (less likely);

 

*  WTF is a Scuttle Box (SB)? The SB is a cavity between the firewall and the dash that the AC system pulls air in through.  It's typically located between the bonnet and the windscreen just under where the wipers attach.  Typically the SB collects water, which then drains out through drains (often in the firewall).  To prevent water entering the AC air is sucked in through a riser that stick up from the floor of the SB .

 

 

 

 





Mike

 
 
 
 




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  # 2048263 3-Jul-2018 13:22
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This has all become way too involved for me. When I was younger I would have happily plunged into this without hesitation, but I am now officially old and I just don't have the personal resources for it anymore. I am handing it to my mechanic on Thursday. I hope he can figure it out. Thanks again to everyone who has tried to help with useful tips. If a solution is found, I will post it here.

 

 

 

 





I don't think there is ever a bad time to talk about how absurd war is, how old men make decisions and young people die. - George Clooney
 


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  # 2048315 3-Jul-2018 13:52
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This reminds me of a European car we had. We found a large amount of water had accumulated in the tyre well were the spare tyre was. This was caused by a design fault with the lights, where water was just able to go through the seal of the light fitting.


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  # 2048532 3-Jul-2018 19:55
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MikeAqua: *  WTF is a Scuttle Box (SB)? The SB is a cavity between the firewall and the dash that the AC system pulls air in through.  It's typically located between the bonnet and the windscreen just under where the wipers attach.  Typically the SB collects water, which then drains out through drains (often in the firewall).  To prevent water entering the AC air is sucked in through a riser that stick up from the floor of the SB .


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  # 2049931 5-Jul-2018 16:24
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Kudos to everyone who left suggestions here. Whoever said the heater was the culprit wins the prize. When we did the hose test my mechanic immediately saw the water gushing out. There is a cylindrical air intake for the heater under the bonnet that is raised so rainwater doesn't get into it. The back of it, up against the firewall, is virtually inaccessible but you can feel around with a finger and there is rust. My mechanic is convinced there is also a hole that is letting the water through, though we can't see it.

 

I am going to take the car in again on Monday. There is moisture everywhere from condensation, under the carpets and even behind the ceiling upholstery. He will remove everything from the interior (I don't feel up to it) and let the car dry for a week. He will also consult a panelbeater to see what can be done about the leak. That is still doubtful at the moment. Getting at it is nearly impossible and would almost require demolition of the car. I am pinning my hopes on some kind of magic Sellys epoxy sealer liquid metal-type substance that can be squirted over everything to keep it going for a few more years. Other than this it is still a good car.

 

 





I don't think there is ever a bad time to talk about how absurd war is, how old men make decisions and young people die. - George Clooney
 


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  # 2049938 5-Jul-2018 16:30
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What's my prize, Rikkitic! :-)

 

For my bonus I suggest you try something like this as a cheap attempt to seal it:

 

http://www.supercheapauto.co.nz/Product/Coolant-Leak-Repair-K-Seal-236mL/357729

 

Never thought of this when this happened to my Subaru, but the heater core may have been too far gone for it. I just bypassed the heater which fixed the problem but created new ones: the no heat in the winter and the window defog required the drying effect of air-con, without any heat making it super cold in the winter.

 

 


 
 
 
 




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  # 2049973 5-Jul-2018 16:48
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kryptonjohn:

 

For my bonus I suggest you try something like this as a cheap attempt to seal it:

 

http://www.supercheapauto.co.nz/Product/Coolant-Leak-Repair-K-Seal-236mL/357729

 

 

I'll let you know what the panelbeater says. Your prize is my great appreciation. If I choose your fix I will add a +1.

 

 





I don't think there is ever a bad time to talk about how absurd war is, how old men make decisions and young people die. - George Clooney
 


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  # 2049977 5-Jul-2018 16:53
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Cool prize! I looked back and saw I wasn't actually the first one to say "heater" so you might have to divvy it up and spread it around... :-)

 

 

 

 

 

 




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  # 2052745 10-Jul-2018 14:46
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The car is now being repaired. My mechanic brought in a panel beater. To do it properly would involve completely disassembling the dash and heater to get at the air intake to weld the leak (as I understand it; this is how it was explained to me). This is not worth the expense on such an old car. Instead, the air intake cylinder is being cut off under the bonnet to enable access to the rusted bit. A new sleeve to fit over it will then be manufactured and glued into place. Again, this is my understanding of how it was explained to me over the phone. I don't fully understand it but I have a long history with my mechanic, in whom I have complete trust.

 

 





I don't think there is ever a bad time to talk about how absurd war is, how old men make decisions and young people die. - George Clooney
 


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  # 2053127 11-Jul-2018 09:19
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Rikkitic:

 

Kudos to everyone who left suggestions here. Whoever said the heater was the culprit wins the prize. When we did the hose test my mechanic immediately saw the water gushing out. There is a cylindrical air intake for the heater under the bonnet that is raised so rainwater doesn't get into it. The back of it, up against the firewall, is virtually inaccessible but you can feel around with a finger and there is rust. My mechanic is convinced there is also a hole that is letting the water through, though we can't see it.

 

 

This is the AC fan riser in the scuttle box that I referred to in my post.  I think I should get the prize tongue-out





Mike

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  # 2053130 11-Jul-2018 09:22
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Rikkitic:

 

My mechanic is convinced there is also a hole that is letting the water through, though we can't see it.

 

 

One of those skinny USB inspection cameras will confirm that for you/him.





Mike

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