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DATE: September, 2008
This TSB supercedes TSB-04-55-007, issued September, 2004, to add Affected Vehicles, advise to install a grommet seal and add instructions to install a cabin air filter. It also changes the PARTS INFORMATION and WARRANTY INFORMATION associated with the changes. Revised information is shown with a <.
The HVAC drain tube can become blocked by internal foam packing material or by external debris (such as leaves, etc.) entering the front cowl area. If this occurs, the case may fill up with condensation and overflow onto the passenger's side floorboard. In some case it can overflow into the blower motor.
If water is found to be leaking onto the driver's side floorboard, it may be due to a deteriorated grommet seal between the HVAC unit and the bulkhead < at the HVAC drain tube. As the vehicle is driven, air flow under the hood forces HVAC drainage back past the grommet and into the vehicle, where it collects on the driver's side floorboard.
To eliminate these conditions, remove the debris and move the internal foam material away from the drain tube as described in this bulletin and install the new grommet seal listed in the PARTS INFORMATION SECTION of this bulletin. Always perform both operations when removing the HVAC assembly.
On certain Endeavor models only, if debris is found in the HVAC case, install a redesigned front deck (cowl) garnish, which will prevent future entry of debris. Install the new garnish listed in the PARTS INFORMATION section of this bulletin if one was not previously installed for this condition.