1999-2004 Grand Cherokke - AC Condensate - Wet Carpet - Another Fix
 

Another easier fix for the AC condensate flooding the passenger side foot well is to make a replacement foam gasket for the opening between the foot well and the engine compartment.

issues:

1. Jeep does not install a rubber drain tube to the plastic horizontal discharge coming from condensate tray through the firewall, so when the foam gasket at the firewall rots out, the water follows the outside of the tube back to and through firewall and under the carpet.

2. I also found that road spray while driving in heavy rain causes water to leak into the footwell through this same hole.

Solution:
Easily Make and replace the gasket from available materials.

When viewed from inside the car (right foot well) there is a 3/8" gap between the drain flange at the bottom of the condensate tray and the firewall. This gap has a foam gasket that rots allowing water to pass through to the foot well when the car is underway.

All of the work described is done from inside the right foot well area.

Pull back the carpet and the sound insulation rubber sheet.

Remove the old foam gasket by any means needed. I used a small screw driver to break it up a little and then pulled it out with my fingers.

I picked up some foam pipe insulation at my home supply store and cut a 1/2" slice of the end of foam pipe insulation with a serrated kitchen knife. This new foam donut is similar to the original but it is cut so it can be opened to fitted around a pipe.

http://denning.com/19le310ia/jeep.jpg

Using both hands, work in a generaous amount of silicone into both sides and edges of the foam donut. Then press it into the gap between the condensate tray flange and firewall. If there is a small gap at the top where the foam donut is cut, use your fingers to push some more silicone into the gap. Also smear silicone around the entire new gasket to add additional seal to the joints between the firewall |foam |condensate flange.

This new siliconed-covered foam gasket stopped all the leakage. I hope it is lasts a few years.

Cost:
$10.00 for the gasket material and silicone
$700.00 to replace the passenger area carpet that had turned into a stinky swamp before I realized there was water in the original carpet pad for months or years.

This photo shows the new foam gasket inserted between the condensate tray flange and the firewall.

http://www.denning.com/19le310ia/jeep2.jpg