This is a sore subject for me as well -- water leaking onto passenger side floor while A/C is on -- seal around circular space where HVAC meets firewall is source for all this. Water runs back from the HVAC drain tube into the vehicle -- clearly a design problem that has caused moldy flooring in that area of the vehicle. Based on internet complaints and fact that Chrysler issued a TSB -- they are aware of the problem; it's been a long standing issue apparently... Better question whether they have fixed this in current and future models ----- my repair solution: a generous amount of caulk applied to area around circular fixture where HVAC box meets firewall on vehicle interior; that and a 2 foot pice of 5/8" heater hose run down the firewall from the engine side that channels water better to the ground and away from weak seal in firewall area -- just be sure to use several zip ties to route that hose away from right front half shaft and the exhaust. So far this seems to be holding up well, even with recirculation feature running full steam... Good luck with yours...

 

Thanks for the information everyone. I too find this to be an annoying problem. I purchased our '06 Gr. Caravan just last fall. Just been using the A/C the past few months--find it hard to believe the previous owners didn't notice this. Anyway, the advice to use 5/8" heater hose worked great. Going on day 3 now. Inside is dry and it seems to be draining great. I also used a dry vac to suck out the drain tube first and stuck some wire in a ways to make sure it wasn't obstructed. I never really noticed it draining underneath the vehicle--and then when I raised the vehicle on the passenger side to do the job it began draining. So perhaps it was clogged? The current design seems a little short sighted--I feel much better with the longer drain tube to the underside of the vehicle.
Thanks again!

 

Stupid question maybe, but where to I find the tube to extend with a 5/8 hose that you guys referring to? Does anybody have a picture? Is inside the car or in the engine compartment? //Thanks

 

it is in the engine compartment, it is the drain for the hvac housing. Is is below the expansion valve and to the right. Probably easier to get to from underneith.

 

I don't have a picture but it is visible from the top side, as if you were changing the spark plugs, and from underneath the vehicle. It is a about a 2" black tube sticking out of the firewall right where it penetrates from inside the vehicle. Just like a previous post says, I routed the 5/6" hose down to bottom of vehicle and secured it in several places with zip ties. I also put a clamp around the hose and the drain tube just to be safe. I attached the hose from under the vehicle and put the clamp on from the top. I have long arms but I think most people could reach it. This may go without saying but raising the vehicle, at the the front, also helps.

It's been several months now for me and I would say it is fixed. Especially since the A/C got a workout this summer in the Texas heat!

 

Thank you guys!