Leaking AC fixed
This has been going on for quite awhile and only occurs in high humidity areas such as south Texas. Been topside a couple times. This time I found two problems...
First: the small hidden black plastic drip pan (2"x8") was fitted smuggle against the tin guarding the AC cabin hole, allowing water coming from evaporator coils to bypass pan and go into cabin. Fitted a couple of shims to tin, opening a gap between pan and tin, allowing water to drip directly from coils into pan. I'm talking 1/8th inch width to allow water through. I could see the water stains where water was missing pan and going into cabin AC hole. The pan is directly under the evaporator coil... you really have to look close. There is also a very large secondary tin pan that seems to serve as a drip reservoir.
Second: the hidden pan drain hole was partially blocked. Actually there are two. I did not find second until I pulled out pan by lifting up evaporator coils. That second one was completely blocked. Drilled out holes to make them larger. I was very lucky to even find the holes. I had my eyes within 2" of the hole before I finally determined there might be something going on in there.
Also cleaned evaporator coils.
What an exercise. Not a fun job. It took me at least 3 hours and boy are my knees and back hurting. The next time it should take me half the time.
Richard & Marilyn
2010 Ford F150, V8, 5.4 liter
2010 Jay Feather Sport 165