[fel44]

Please help me fix this wet carpet problem. 1994 dodge caravan 3.0, last year, I started seeing front carpet both driver and passenger side wet, so I pulled the a/c/heater box out from the van because I suspected that the heater core was leaking again.

For a while, many weeks past the carpet dried up then got wet again when it rain even while the a/c /heater box was still out of the van and the van being parked for many weeks, without driven anywhere.

I searched here for an answer to my issue, found something about 97 Voyager, "The cowl drain hoses underneath the wiper box are probably plugged with leaves....".I then removed the cover that goes over the wiper cowl to clean out leaves and debris, I did not see any drain hose or any hose anywhere there..

Does this van has the same drain hose or a different drain system? I installed the a/c heater box back in the van few months ago and yesterday after some heavy rain, the front carpet is wet again both side especially passenger side.

How can I fix this wet front carpet problem? Please help me ,I really want this fix as soon as possible,thanks.

Felix.

 

[ImperialCrown]

1984-1995 AS would be the minivan generation before the 1996-2000 NS minivan and the cowl drain system would be different. Your drains are off to the left and right ends of the cowl plenum chamber, into the front fenders and drain out onto the ground behind each wheel opening.
You need to locate the water entry point. The HVAC does have the fresh air intake in the cowl plenum and if the water can't drain from this area, it will enter down into the HVAC housing and leak onto the right front carpet.
With the wiper screen removed, run water into the plenum area with a garden hose under low pressure. Watch for a plugged drain in the cowl or have a helper inside the van watching for water dripping. Many times a cowl full of water will leak onto the floor after a sharp turn after an overnight rainstorm, for instance.
You also want to be sure that the A/C evaporator drain coming out of the right side firewall is clear of debris. This offers another escape for water build-up.
The rubber antenna grommet where the cable enters the body behind the right kick panel is also a common water leak point if the grommet got dislodged from its sheetmetal opening.
You may want to remove the carpet for washing and drying to avoid moldy odors. The jute backing may have to be discarded as once this material starts to stink, there is little remedy for it.

 

[fel44]

1984-1995 AS would be the minivan generation before the 1996-2000 NS minivan and the cowl drain system would be different. Your drains are off to the left and right ends of the cowl plenum chamber, into the front fenders and drain out onto the ground behind each wheel opening.
You need to locate the water entry point. The HVAC does have the fresh air intake in the cowl plenum and if the water can't drain from this area, it will enter down into the HVAC housing and leak onto the right front carpet.
With the wiper screen removed, run water into the plenum area with a garden hose under low pressure. Watch for a plugged drain in the cowl or have a helper inside the van watching for water dripping. Many times a cowl full of water will leak onto the floor after a sharp turn after an overnight rainstorm, for instance.
You also want to be sure that the A/C evaporator drain coming out of the right side firewall is clear of debris. This offers another escape for water build-up.
The rubber antenna grommet where the cable enters the body behind the right kick panel is also a common water leak point if the grommet got dislodged from its sheetmetal opening.
You may want to remove the carpet for washing and drying to avoid moldy odors. The jute backing may have to be discarded as once this material starts to stink, there is little remedy for it.

Thanks for giving me good pointers to begin with.As far as the A/C evaporator drain coming out of the right side firewall is concern, I can say for sure that it is clear of debris. Before installing the A/C Heater box back,I cleansed thoroughly inside the box before installing the heater core. evaporator and a new drain hose. I have not yet installed the lines,extention valve,drier/filter,compresor and condenser so the A/C is not activated yet,only the heater is activated for use from time to time.

Before the last front carpet wetting problem, I removed the wiper screen and cleansed out every debris on site, left and right as far as I can see. I couldn't see far ends into the plenum where the water drain is suppose to drain out onto the ground. In addition to the garden hose test, maybe the front tires/wheelhouse splash shields need to be removed in order to see where the water actualy drain onto the ground to rule out if there is blockage there?


Does the A/C box has to be removed to get access to the rubber antenna grommet from inside the van? Also regartding removing the carpet for washing,is that involves removing the whole carpet or there's a division between the front and rear?

Thanks again

Felix.

 

[ImperialCrown]

You may want a good service manual if you are going to service the vehicle further. It just makes it easier to read a repair procedure order of disassembly or to see a picture on how something comes apart.
A main public library may have more detailed (or even factory) service manuals to take out on loan or to photocopy. Some large city libraries might have an internet subscription to Alldata.
Where the HVAC housing meets the cowl plenum there should be a foam gasket to prevent air leaks and a raised sheetmetal lip on the plenum side to keep water out. There is a black plastic shield covering the actual HVAC air intake.
Tree debris is the worst offender for plugging up water drains in cowl plenums and sunroofs.
You would only have to pull the front wheel inner fender splash shields only if you didn't see water draining onto the ground.
The antenna cable grommet is visible, but tight to get at from inside the vehicle. You don't have to remove the A/C housing to access it. If the cable grommet has dislodged from its hole, it may be easier to get your hands on it to reseat it if you have the right inner fender shield pulled away. Dried water leak trails may appear as whitish drip streaks from the source of the leak.
Pulling out the carpet will require the removal of the seats and floor trim pieces. It is a one-piece carpet AFAIK. Again a good service manual used as a guide will help here.

 

[A.j. Schreiber]

have you recently had the windshield replaced?

 

[fel44]

You may want a good service manual if you are going to service the vehicle further. It just makes it easier to read a repair procedure order of disassembly or to see a picture on how something comes apart.
A main public library may have more detailed (or even factory) service manuals to take out on loan or to photocopy. Some large city libraries might have an internet subscription to Alldata.
Where the HVAC housing meets the cowl plenum there should be a foam gasket to prevent air leaks and a raised sheetmetal lip on the plenum side to keep water out. There is a black plastic shield covering the actual HVAC air intake.
Tree debris is the worst offender for plugging up water drains in cowl plenums and sunroofs.
You would only have to pull the front wheel inner fender splash shields only if you didn't see water draining onto the ground.
The antenna cable grommet is visible, but tight to get at from inside the vehicle. You don't have to remove the A/C housing to access it. If the cable grommet has dislodged from its hole, it may be easier to get your hands on it to reseat it if you have the right inner fender shield pulled away. Dried water leak trails may appear as whitish drip streaks from the source of the leak.
Pulling out the carpet will require the removal of the seats and floor trim pieces. It is a one-piece carpet AFAIK. Again a good service manual used as a guide will help here.

Thanks very very much, this van for some reasons, is for keeps.Hence as you helpfully suggested,I'm already in subscription with Alldata & Mitchelle1 since I think, 2010/ 2011. I Already purchased Chilton for Chryler-Caravan/Voyager/Town & Country 1984-95 Repair Munual #20300 ,and 1994 service manual-Town & Country,Caravan,and Voyager, and another one I can't find right now nor remember its name,I think its the gas version manual for 1994 Dodge caravan, purchased that version by mistake from ebay.They're all very helpful indeed. I'm still looking if there is a manual for complete body componenets removal & installation for this van at ebay or elsewhere.

They help me great deal for some minor repairs am able to accomplish.though some directions are not clearly explained or detailed enough, some directions even can't be found for some repairs, yet for the most part, these manual are very very helpful for tree-shade mechanic like me.

I'll follow all your directions/suggestions to find the leak/s to fix.Finding the leak is a bigger job for me, because water leaks can come from unsuspected sources sometimes.

Very much appreciated your help. Thanks.

Felix.

have you recently had the windshield replaced?

Never replaced the windshield since the van was purchased new (1994)

Thanks/

Felix.

 

[A.j. Schreiber]

well it sounds like it isnt related to the heater core so thats good. I'd look at where the air inlet for the A/C blower is and run a garden hose positioned in various places to help locate the leak.

 

[fel44]

well it sounds like it isnt related to the heater core so thats good. I'd look at where the air inlet for the A/C blower is and run a garden hose positioned in various places to help locate the leak.

Thanks, the carpet wetting was detected before the HVAC housing was removed from the van,then the soaked carpet was dried up, then the rain came and the carpet was wet again while the HVAC housing was still out of the van,so it couldn't be the heater core.Nonetheless the heater core and other parts were replaced inside the HVAC housing, then the HVAC housing was installed after I was unable to locate the source of the leak.

The rain came again this time and the front carpet was wet again.Untill the leak source/s is detected and fix,the front carpet will continue to get wet everytime it rains.I'll try to find time this week God's willing to check it out.
Thanks again.

Felix.

 

[oslekcim]

My solution: Keep the drains clear of leaves. Use forceps and a blast from an air compressor. If that is insufficient you can unscrew the slottted cover below the windshield after pulling the wipers, and clean out the hidden pan and drains.

Background: I park my 1996 NS minivan on the street, often under trees that drop seeds and leaves. After a major rainstorm water would drip on the right front passenger's foot and wet the carpet. I could hear the water in the hidden pan below the windshield, sloshing left and right when I cornered!