I have an 04 6.6. A month ago after returning from a long trip I noticed that the carpet on the drivers side was soaking wet and water was sloshing around in the heater housing. The A/C had been on and the dealer determined that the HVAC evaorator case drain was blocked by the heater case seal foam. To make along story short every I take the truck on along trip and use the a/c I get a small amount of moisture in the carpet on the drivers side. Not a lot, but the carpet is damp, and you can see moisture on a small area on the the back of the floor mat. The truck has been back to the dealer 3x and they say they can't determine what is causing the problem. Fortunately the truck was on warranty at the time of the initial problem but know it is not and I am going to have to pay evry time it goes back regardless of whether or not they fix the problem. Any help will be greatly appreciated. Thanks.

Do you have the problem only when the AC is used ???????

If you do then I would start there, if the drivers side is getting wet then I think the AC is ruled out because the drain is on the passenger side.......

Do you have CAB LIGHTS, ON-STAR-XM.........possibly the leak is around the gaskets on those roof mounted accessories.....

If you do a search of the FORUM there was a thread where some members had leaky windshields and other problems.........I think most got the problems solved.

Good Luck,

T:cool: NY
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if your drain is pluged on your evaporator who knows where the water will come out but it will come out, if its only happening when the AC is on then you can about be sure what the problem is, try running something up the drain line to clean it out, like Tony said its on the passenger side, there is probably a tray on the bottom of the evap and when the condensate fills it up you get it on the floor. Do you have a puddle when you park with the AC on?

if your drain is pluged on your evaporator who knows where the water will come out but it will come out, if its only happening when the AC is on for along time then you can about be sure what the problem is, try running something up the drain line to clean it out, like Tony said its on the passenger side, there is probably a tray on the bottom of the evap and when the condensate fills it up you get it on the floor. Do you have a puddle under your truck when the AC is on?

Thanks guys ! It definitely was the a/c drain tube that was blocked, the water was on the drivers side and there was lots of it. The passenger side was dry. I'll bet that they didn't check the tube itself. Right know the a/c dumps the water on the ground like it should. Only a small section of the carpet gets damp, but sooner or later, the carpet will stink and the floor will rust if I don,t look after it. By the way, they say that they ran the truck for 5 hours and couldn,t find the leak. The carpet was damp when I picked it up which tells me that they did not look too hard to see where the water was coming from. It would appear that they were only concerned as to whether or not the a/c was draining. Thanks again I will let you know how I make out.