Chrysler Repair: 2001 T & C Wet Floorboards, mileage cars, water leaks

Question
Doug,
 I've brought my minivan to the dealership three times in an effort to fix wet floorboards for the front two seats.  They've cleaned out the A/C condenser drain, installed the longer drainage hose IAW the TB and told me they went back in and sealed every known place the condenser could leak from.  Unfortunately, the floorboards continue to be wet, even after drying them thoroughly with a fan for several days.  The moisture appears to be water, does not have an odor to it, and occurs in dry or wet conditions.  Any ideas?
Thanks
Tom  

Answer
Water leaks... Bad.

These aren't fun ones to find so I feel the technicians pain here.  I've replaced a few ruined carpets too on low mileage cars so I definitely understand YOUR point of view too.

There is a service bulletin for installing an a/c drain tube o-ring.  This o-ring is supposed to prevent water leakage from the passenger side of the vehicle where the drain tube for a/c condensate exits the vehicle.

The service bulletin number is 24-001-06 and in that the dealership technician should be able to order the part needed to correct the condition described in there.

If this does not fix the problem then he or she will need to do additional leak checks.  Also, the technician will need to isolate the problem by determining if it's truly a water leak or an a/c condesate leak.  Running the vehicle with the a/c on, in a shop or outside on a nice day will be the only way to do this.

Water leaks can be very tricky because there's alot of variables that can make or break the diagnostic procedures.  When you or the tech is dealing with a water leak there's a few things they need to ask themselves in order to start ruling things out.
1. Does this happen every time the a/c is on?
2. Does water leak in when it's raining?
3. Does water leak in only while driving, parked or both?
4. If parked only what position is the car in?  nose down, up, left side higher or lower than right?
5. Does this problem happen only when raining and how heavy?
6. Does the vehicle have a sunroof?  
7. Are the drain tubes clear?  Unpinched?

After checking these things the technician and you need to understand how a vehicle is designed.  Years ago manufacturers designed cars to keep water out.  This made water leaks more prevelant because things had to be sealed everywhere.  Now, manufacturers got smart and realized that it's easier to control water intrusion than it is to stop it.  Sunroofs are going to leak, let's direct the water to the A and B-pillars.  Convertible tops are going to leak, direct the water to the pinch welds so they can leak out there.  And with windows they put felt and rubber to deflect some water and have drain slots molded in to the metal to allow water to drain out instead of filling up the door liners.

Next the technician needs to know how to do a water leak check.  If you tell him it's only leaking inside the car with the a/c running then there should never be a drop of water to be sprayed on it.  This will add to the confusion and probably the expenses too.  If you have actual rain water coming in then the tech needs to know to start low and work his/her way up.  They should start at your antena for about 20mins and slowly start moving the hose higher.  The sunroof (if equipped) should be the last spot to check.

The mechanic MIGHT have created more problems if they sealed up everything nook and cranny they could.  If it doesn't leak then great.  But what if these parts ever have to come out for service at a future date?  If the sealer is strong and the component is plastic you can bet it's going to break.
Doug