Taurus Car Club of America : Ford Taurus Forum banner
1 - 20 of 23 Posts

·
Registered
Joined
·
136 Posts
Discussion Starter · #1 ·
Hey guys,

I just become a member of your site and hope I'm posting this in the right place. I've got an annoying problem with a water leak and I'm hoping someone can help.

I've got a 2003 Taurus with 105,000 kms (65,000 miles). Just before Christmas I noticed that the front passenger side floor was damp. I thought perhaps it was caused by water on the floor mats which had spilled over. Turns out I was wrong. A few weeks ago I was doing a spring cleaning and noticed the carpet was a lot more wet then before. I pulled it back and found black mould on the material underneith (towards the back where the firewall was). The material was all damp. I should point out that there wasn't any major ponding or puddles. It just looks like the water has been slowly leaking in. I'm a bit concerned because there's a rubber drain plug which isn't protected by that yellow foam which coats the rest of the floor pan. There's a small bit of surface rust which has now formed and the last thing I need is rotting floors.

It's my understanding that this is a common problem on these cars (leak). A friend at Ford printed me a copy of the TSB which claims water can leak in from around the cabin filter tray. So I bought a new cowl, rain hat extension, and some clear silicone to reseal the tray. I haven't been able to do anything because of the cold weather and rain. It looks like the original owner of the car had already installed the rain hat extension (the rubber strip that fits onto the rainhat/flap). I'm a bit puzzled as to why they didn't reseal the cabin filter tray. I'm assuming it's the original factory sealer because it's black foam and the TSB recommends a silicone.

The TSB also talks about removing a piece of tape and filling the hole with silicone. I have looked at the diagram and can not find any tape or hole.

Today I pulled the cowl off and put a few drops of green food colouring into a bottle of water. I then poured this stuff all around the base of the cabin filter tray. Not one drop of green water dripped into the car. It drained out of the fender and also out of the rocker panel covers.

So I'm wondering..... could this water leak be coming in from somewhere else??. The floor mats are always dry and it's obvious that the water is leaking in from underneith the carpet somewhere. Could it be the heater core?.

I'm the 2nd owner of this car. The vehicle service history indicates that the heater motor had been replaced under warranty around 2006. The new one still works. So I'm guessing that maybe they had a problem with water leaking too.

I'd really appreciate any help. I've been on numerous car websites and nobody has been able to help.
 

·
Registered
Joined
·
136 Posts
Discussion Starter · #2 ·
Here's some pictures. The first picture shows the cowl removed and the cabin filter tray exposed. Can anyone confirm that it's got the original black factory sealer along the base?. (it's foam).

Second picture shows the carpet pulled back and where the mould has formed. the water is obviously coming in from around the firewall based on where the mould has formed.

The black spot you see on the floor is where I've sprayed rust paint. There's a plug there.
 

Attachments

·
Premium Member
Joined
·
7,307 Posts
Search is your friend.
There is another area that can leak.
It is the air conditioner drain that comes out of the firewall behind the engine.
There is a sponge seal around the drain that allows water to come into the cabin.
Silicon around that drain and see if that solves the problem.
I did that to 6 Tauri: our 4, my moms and my sister in laws!!

When the leak stopped, I pulled up part of the carpet, tore out the old pad and ran a fan in that area overnight to dry things out. Then I put in new carpet pad that I had left over from our basement carpeting. :)
 

·
Registered
Joined
·
136 Posts
Discussion Starter · #5 ·
Search is your friend.
There is another area that can leak.
It is the air conditioner drain that comes out of the firewall behind the engine.
There is a sponge seal around the drain that allows water to come into the cabin.
Silicon around that drain and see if that solves the problem.
I did that to 6 Tauri: our 4, my moms and my sister in laws!!

When the leak stopped, I pulled up part of the carpet, tore out the old pad and ran a fan in that area overnight to dry things out. Then I put in new carpet pad that I had left over from our basement carpeting. :)
Thanks for the response.

I notice that there's a few of these round sponge seals on the firewall. I'm assuming the one that you're referring to for the A/C is on the passenger side?. I'm not sure if I'm looking at the same thing but I did notice upon removing the carpet that there's a round seal surrounded by a sponge like material that is on the firewall with a hose running out of it (just below the glove box). Is this the same thing you're talking about?.

I've only had the A/C on once this year to cool down the interior one mild day. But that's the only time it's been on because we're still in April. Could this thing still leak regardless of being on?.
 

·
Registered
Joined
·
833 Posts
Rain water can also get up in there. There's a plastic tube about an inch wide on the passenger on the side in the engine compartment on the firewall. Take a tube of clear silicone sealant and go all around it (not inside it...). Feel free to go overboard and dont worry about being pretty, noone can see it. There's also another are where these leak, the base of the cabin air filter. scrape up all chunks of extra sealant there and reseal with the same clear silicone. when this happened to my car I took the carpet out, dried it in the sun, then scraped off the mold and mildew. You don't wanna be breathing that ish in.
 

·
Registered
Joined
·
136 Posts
Discussion Starter · #7 ·
Rain water can also get up in there. There's a plastic tube about an inch wide on the passenger on the side in the engine compartment on the firewall. Take a tube of clear silicone sealant and go all around it (not inside it...). Feel free to go overboard and dont worry about being pretty, noone can see it. There's also another are where these leak, the base of the cabin air filter. scrape up all chunks of extra sealant there and reseal with the same clear silicone. when this happened to my car I took the carpet out, dried it in the sun, then scraped off the mold and mildew. You don't wanna be breathing that ish in.
I think I know the thing you're talking about. Would this plastic tube/hose that goes through the firewall have a rubber gasket or plug going around it?. The one I'm thinking of is right on the firewall. You basically have to pull the carpet back to see it.
 

·
Registered
Joined
·
136 Posts
Discussion Starter · #8 ·
I was hoping someone could confirm whether the car has the original sealer going around the cabin filter tray (see picture). Did ford use the black foam in the factory?. That's what is on the car right now.

I'm still planning to re-seal this tray with clear silicone. I have to wonder whether the water is really leaking in from there because I poured 2 large measuring cups of water around that tray and not a single drip of water appeared inside the car.
 

·
Devoted Member
Joined
·
2,426 Posts

·
Registered
Joined
·
23,579 Posts
Ive been able to stop all of my pass. floorboard water problems by sealing around the ac drain on the pass. firewall.
 

·
Registered
Joined
·
136 Posts
Discussion Starter · #11 ·
This is a known issue on G4's. Water is getting in at the base of the cowl near the cabin air filter. You need to do the "Rain Hat" fix.
Check out these links:
http://www.taurusclub.com/forum/82-...e-rain-hat-extension-covers-cabin-filter.html
http://www.taurusclub.com/forum/att...-filter-fordtauruswaterblowercase_sb04153.pdf
It looks like you have the original foam tape seal on there still, a known failure spot. The above PDF file is the factory TSB on the subject.
Thanks for the links. I found it interesting that the previous owner had already installed that rainhat extension (the rubber strip) but didn't re-seal the base of that cabin filter tray. There doesn't appear to be much room to work with. I'm guessing that only the front of that tray needs to be sealed?.

On the TSB... it talks about removing a piece of tape and filling the hole. I can't find any such tape or hole. Whereabouts are they talking exactly?.

I took 2 measuring cups with water (I added green food colouring) and poured it all around the base of that Cabin filter. Not one drop of water came in. Today it rained and when I checked the floor was damp. Thankfully I had rags to absorb it.

I'll be doing this TSB hopefully this weekend if the weather is good. If this doesn't work I don't know what I'll do.

I had a similar problem with my 2001 Mustang. These cowls don't sit against the glass very well.
 

·
Registered
Joined
·
833 Posts
If I remember correctly the tape theyre referring to is in the corner near the fender/windshield. But the leak you're trying to fix is dripping down the firewall, right? If it's leaking down the filter housing, you have to remove the blower motor to see the water coming in (3 screws, one electrical connector). You might want to look at this anyway, if it's rusted to ish then it's been getting wet and won't last long.
But the a/c drain... you want to seal it from the OUTside. Just look behind the engine, passenger side, there is only one plastic tube sticking out of the firewall. Take that tube of sealant and stick in between the drain and the firewall insulation and squeeze. Go ahead and make a mess, get as much of it shoved in there as possible, without getting inside the drain.
No the cowls don't sit well. Mine was warped, way off the glass. So I bought a new one. A year later it's warped off the glass again. But whatever, I don't have any leaks anymore, that's just aesthetic. Good luck, and get that carpet out of the car, get the mold and mildew off of it, and btw, the rear seat floor board may have been wet too, so yes, you do want to pull the whole carpet out.
 

·
Registered
Joined
·
136 Posts
Discussion Starter · #13 ·
If I remember correctly the tape theyre referring to is in the corner near the fender/windshield. But the leak you're trying to fix is dripping down the firewall, right? If it's leaking down the filter housing, you have to remove the blower motor to see the water coming in (3 screws, one electrical connector). You might want to look at this anyway, if it's rusted to ish then it's been getting wet and won't last long.
But the a/c drain... you want to seal it from the OUTside. Just look behind the engine, passenger side, there is only one plastic tube sticking out of the firewall. Take that tube of sealant and stick in between the drain and the firewall insulation and squeeze. Go ahead and make a mess, get as much of it shoved in there as possible, without getting inside the drain.
No the cowls don't sit well. Mine was warped, way off the glass. So I bought a new one. A year later it's warped off the glass again. But whatever, I don't have any leaks anymore, that's just aesthetic. Good luck, and get that carpet out of the car, get the mold and mildew off of it, and btw, the rear seat floor board may have been wet too, so yes, you do want to pull the whole carpet out.

UPDATE...

It's been 8 days since I re-sealed the cabin filter tray and so far there hasn't been any leaks! :D. It's rained here almost every day and the floor is dry. I had the carpet pulled back and rags on the floor just in case. So rar it's still dry.

The water did appear to be dripping down the firewall because all the material underneith the carpet was wet and the mold started against the firewall. The funny part is that there was a rust stain near the wheel well but it looks like it's been there for awhile and may have been a previous leak that the original owner fixed (the service history indicates they replaced the heater motor in 2006. The rain hat extension was already on the car but they never sealed the tray).

I removed the cowl and scraped as much of the original foam sealer away from the tray. I then re-sealed around it using clear silicone. I also installed a new rain hat extension and new cowl. I also sealed around several hoses that were sticking out of the firewall.

I'll have to double check on this A/C hose. I'm sure I sealed around all the hoses but I thought there were several of these hoses coming out of the firewall. It's very hard to reach because there's not much space. You wouldn't happen to have any pics of this AC hose?.
 

·
Registered
Joined
·
23,579 Posts
Ac drain is not a hose, just a 1/2-1 in. long oval-shaped black plastic tube protruding through the pass. firewall below and towards the pass. side from the 2 heater hoses. Simply fill with silicone the foam (sponge) recess surrounding the tube. I applied it using my fingertips. Have paper towels or rags for clean-up, lol. Cant remember if i removed the pass. wheel or simply turned it hard left or right to reach in there?
 

·
Registered
Joined
·
13 Posts
been awhile since this subject has been brought up..I just purchased a 2003 taurus sel premium. very nice car. Since I am a auto tech, I wanted to take care of all the maintaince so I have my own start date. I replaced the cabin air filter, it was nasty. After, when it rained, the carpet got wet. Don't know if it ever did it before, because even though I live in Seattle, Its been dry for the most part since I purchased this car. yesterday, I followed the TSB from ford, and purchased the extended rain cap on line for much less then the stealership wanted to charge me...Sunday, I will pull of the R/f wheel, and liner and take care of sealing up the a/c drain...I also noticed the blower motor has a rusty fininish on the bottom of it. anyway,.I hope this will cure the problem, because I love this car.
It has 142,000 miles on it, 3.0 duratec engine....Also Sunday, a tranfilter and fuel filter will be installed. I already replaced the front and rear brake pads/shoes, drums, rotors and calipers.... inner/outter tie rod ends, and l/f headlamp and both bulbs, (super whites ) then adjusted. Still Needs 4 new tires before winter, all 4 are different brands.. leather interior is excellent, but carpet is stained, and I will eventually replace, but I did shampoo it twice, and the car smells better...I purchased some touch-up paint, because the prior owner must of lock themselves out, and used a slim-jim on the paint by the doors and chipped the hell out of them...The prior owner had a dog that chewed up some belt buckle covers, and dug a hell of a hole in the headliner, which I was able to repair by cutting away the bad stuff, and gluing in new...not perfect, but it worked, getting the whold headliner is impossible w/o taking out the windshield..anyway..THANKS TO ALL for all the great information on this site.....
 

·
Registered
Joined
·
10,940 Posts
been awhile since this subject has been brought up..I just purchased a 2003 taurus sel premium. very nice car. Since I am a auto tech, I wanted to take care of all the maintaince so I have my own start date. I replaced the cabin air filter, it was nasty. After, when it rained, the carpet got wet. Don't know if it ever did it before, because even though I live in Seattle, Its been dry for the most part since I purchased this car. yesterday, I followed the TSB from ford, and purchased the extended rain cap on line for much less then the stealership wanted to charge me...Sunday, I will pull of the R/f wheel, and liner and take care of sealing up the a/c drain...I also noticed the blower motor has a rusty fininish on the bottom of it. anyway,.I hope this will cure the problem, because I love this car.
It has 142,000 miles on it, 3.0 duratec engine....Also Sunday, a tranfilter and fuel filter will be installed. I already replaced the front and rear brake pads/shoes, drums, rotors and calipers.... inner/outter tie rod ends, and l/f headlamp and both bulbs, (super whites ) then adjusted. Still Needs 4 new tires before winter, all 4 are different brands.. leather interior is excellent, but carpet is stained, and I will eventually replace, but I did shampoo it twice, and the car smells better...I purchased some touch-up paint, because the prior owner must of lock themselves out, and used a slim-jim on the paint by the doors and chipped the hell out of them...The prior owner had a dog that chewed up some belt buckle covers, and dug a hell of a hole in the headliner, which I was able to repair by cutting away the bad stuff, and gluing in new...not perfect, but it worked, getting the whold headliner is impossible w/o taking out the windshield..anyway..THANKS TO ALL for all the great information on this site.....
I had the water thing in my '01 but not any in my '03. The newer had the rain hat extension but not my '01. I got one for a $1 at local pick a part. It just slips on, no tools required.

I had water in the blower. I took it out, and blew the water out with compressed air and drilled a oil hole in the bearing cover and oiled it. Been working fine for over a year. It was quite clear the water came in through the filter as the filter was wet, and the water was right below it, except for what was in the carpet.

I think Ford gets about $35 for this part. Bummer.


Good luck with your car.

-chart-
 

·
Registered
Joined
·
13 Posts
bummed out again. thought the leak stopped, it did not leak last night at all, big rain storm all night, I was happy, but after the car was sitting all day at work, and rainning most the day, I got in the car after work, and I smelled the "wet dog" smell. Went and check, wet carpet again, comming from the center of the pass. side of the car... directly under the drain area. I don't understand how water can get to this drain area, I gooped the hell out of the area around the drain on the firewall side, and it still soaked the carpets. any ideas?????????????????????????????????
 

·
Registered
Joined
·
13 Posts
took everything apart, even the cowl on the engine side....seems water likes to seep out and under that foam weatherstrip and down the firewall...and into the a/c drain seal. it no longer leaks from there, but last night, after a down pour, I check the pass. carpet again, and found it damp, but not up by the firewall like before, but in the middle, like its comming from the door. I cleaned out the sun roof drains, but they were working fine...wtf????????????????
 

·
Registered
Joined
·
13 Posts
still working on leak..seems to have stopped, but having problems finding the extension kit as per the tsb....I ordered on last month on e-bay, but the seller took my money, and has not delivered part. So I am going through the steps to get my part or money...first problem I have ever had buying on e-bay.....
 

·
Registered
Joined
·
10,940 Posts
still working on leak..seems to have stopped, but having problems finding the extension kit as per the tsb....I ordered on last month on e-bay, but the seller took my money, and has not delivered part. So I am going through the steps to get my part or money...first problem I have ever had buying on e-bay.....
I think I could make a temporary out of duct tape.:lol2:

-chart-
 
1 - 20 of 23 Posts
Top