Dodge Repair: Condensation Overflow inside cab of truck, caravan voyager, cherokee international


Question
Hi:  I have a 2002 DODGE DAKOTA 4X4 with 8000 miles.  I noticed that the floor on the passanger side of the inside cab was SOAKED.  There are also pools of condensation/water in the rear of the cab (I have an extended cab) where you could hold beverages.  I used to have an old 1989 RAMCHARGER and it had a black plug inside the engine/firewall that I could unplug and clean myself as it would get dirty and this solved that problem.  That was an OLD TRUCK and I could locate it and get to it rather easy.  Am I experiencing the same problem from running the A/C all summer and now there is overflow from a clog somewhere?  I will take it to the dealer if you think it is something that I cannot do myself.  Thanks in advance for your time and any advice is most appreciated!

Mark

Answer
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-010-04, DATED
APRIL 29, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL
MODELS AND REVISED LABOR OPERATIONS.
SUBJECT:
Passenger Compartment Floor Water Leak
OVERVIEW:
This bulletin involves sealing the opening for the evaporator hose/drain tube with RTV
sealer.
MODELS:
2001 - 2004 (AN) Dakota
**2004 - 2005 (CS) Pacifica**
2001 - 2003 (DN) Durango
**2002 - 2005 (KJ) Cherokee (International Markets)**
2001 - 2004 (RS) Caravan, Voyager, Town & Country
NOTE: **This bulletin applies to KJ vehicles that are Right Hand Drive (RHD).**
SYMPTOM/CONDITION:
Water may enter the passenger compartment between the HVAC housing and the
bulkhead. A foam seal is used to seal the heater housing to the bulkhead. Condensation
from the A/C evaporator can run along the evaporator drain tube and enter the passenger
compartment if the seal between the HVAC housing and the bulkhead is not sealed
properly. This will result in wet passenger compartment carpet when the air conditioning is
operating.
DIAGNOSIS:
If the symptom exists, perform the Repair Procedure.
PARTS REQUIRED:
Qty. Part No. Description
AR 04467708 RTV Sealer
NUMBER: 23-010-04 REV. A
GROUP: Body
DATE: September 9, 2004
REPAIR PROCEDURE:
Locate the evaporator hose and drain tube opening in bulkhead at the rear of the engine
compartment. Apply a bead of RTV sealer, p/n 04467708 or equivalent, to the perimeter of
the opening to seal the joint between the bulkhead and the HVAC gasket and the joint
between the drain tube and the HVAC gasket.