Auto Parts: condensate leak, thermostatic switch, chevy venture

Question
I have a 2003 chevy venture, the carpet under the drivers feet is getting soaked when the a/c is on. It is not dripping from above, seems to be coming in under the carpet. The condensate drain is a grommet on the firewall, no tube or hose going to the bottom of the van. first I tried a wire in the grommet hole, didnt work carpet stll getting wet, next I dismantled everthing under the dash to get to the condensate drain pan, got close enough to run water thru a garden hose into the pan, came out grommet in firewall fine. thought problem was fixed, put a fan on the carpet to dry it that night, next day drove the van 3 hours with a/c on and the carpet and padding was soaked

Answer
    First I would check that the pan is properly leveled; it should tilt slightly towards the drain.  Flooding it with water would still cause the grommet to drain, but small amounts of water might be sloshed back into the cabin.  The fact that it is not dripping but oozing under the carpet makes one think that the grommet may have a tear or leak in it that allows some of the drain water to travel down the inside of the firewall instead of all going down the outside of the firewall.  I'd also be suspicious of mildew or other growth in the system (due to the undrained water) causing the problem.  GM vehicles rarely suffer from this malady, although some other manufacturers get it a lot.  I would also be suspicious of icing on the evaporator.  There is a cycling of the compressor that is designed to prevent ice formation, but an underfilled system or malfunctioning thermostatic switch could cause more water to be produced than the system is designed to deal with.