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Old 06-18-2014, 07:53 PM
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Help needed: Not sure what to do about this leak

I've been taking on water in the front passenger side floor pan. I can see the water streaks coming from the firewall up high behind the glove box area.

I've looked at a few posts and those didn't quite address the issue. I had the cowl all apart and RTV sealed the air intake box, like it was suggested. Now I no longer get little drips out of the blower motor. I took a hose with a light trickle and confirmed a small a-pillar leak due to the soft top, but nothing significant. I went all around the cowl and windshield and nothing.

I then proceeded to the firewall on the engine side. I started low where the AC drain is. I realize it has been suggested to put a piece of hose with a bend in it over the exit. I had the hose right on it and nothing. I then moved up to a bracket just above that and nothing. When I put the hose just above the rectangular hole where the AC lines run through the firewall, it poured into the passenger side pan with the same water-run pattern as I've seen in the past.

I'm not sure how to handle this. I would like to do it right. I was thinking about taping z-metal drip edge over it with high-temp aluminum tape, then RTV sealing the split rubber grommet, but I fear that water may be getting in through or around the open cell foam. Help is appreciated.

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Old 06-18-2014, 08:07 PM   #2
Knows a couple things...

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That drain on the firewall can clog with gunk which can cause the condensation from the a/c to backup into the passenger compartment. That has never happened to me but I read that some have cleaned it out with a flexible wire inserted up into the drain hose to help break up the crud where it will be flushed out with more condensation from the a/c.

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Old 06-18-2014, 08:18 PM
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That drain on the firewall can clog with gunk which can cause the condensation from the a/c to backup into the passenger compartment. That has never happened to me but I read that some have cleaned it out with a flexible wire inserted up into the drain hose to help break up the crud where it will be flushed out with more condensation from the a/c.
Thanks, Jerry. I actually did that and it was clear. But when the water hit the area where the lines run through, it ran in just like it does during a heavy rain.
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Old 06-19-2014, 04:14 AM   #4
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Thanks, Jerry. I actually did that and it was clear. But when the water hit the area where the lines run through, it ran in just like it does during a heavy rain.
Thanks for the tip. I too get water coming in at times, I haved followed every thread on this subject but no success so far. I have noticed that if I park my TJ pointing uphill the leak doesn't occur. I will check for water coming in via those lines. As for sealing this, I often use "Sikaflex", its messy but if you don't like the seal "job" just wait for it to cure and pull it out.
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Old 06-20-2014, 08:11 AM
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Likewise. Let us know your result.
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Old 07-02-2014, 09:39 AM
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So yep, I packed 3M silicone paste into that area and no more link.
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Old 07-02-2014, 10:14 AM   #7
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So yep, I packed 3M silicone paste into that area and no more link.
Which area are you talking?
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Old 07-03-2014, 07:59 AM
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Which area are you talking?
Check the photo at the top. I packed silicone grease around where the AC and heater lines pass through the firewall. There is an open cell foam block around split rubber grommets. They are not a tight fit, therefore, water was running down under the hood hinge, down the firewall, and right into those spaces.
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Old 07-03-2014, 09:26 AM   #9
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I will check for water coming in via those lines. As for sealing this, I often use "Sikaflex", its messy but if you don't like the seal "job" just wait for it to cure and pull it out.
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Old 07-03-2014, 02:17 PM
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I will check for water coming in via those lines. As for sealing this, I often use "Sikaflex", its messy but if you don't like the seal "job" just wait for it to cure and pull it out.
I used this and it worked like a charm Amazon.com: 3M 08946 Clear Silicone Paste - 8 oz.: Automotive. I wanted something that I could wipe off and reapply in the event of a repair involving the AC or heater lines.

It was a moderate downpour all morning and I just confirmed that my carpet and pan underneath are bone dry.

There is a split rubber grommet around the AC lines, but not the heater hoses. You can stick your finger in between the hoses and feel that it is open. I packed the paste in there, all around the hoses, around the AC lines, and around the open cell foam block where it meets the firewall.

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