Is this a common problem?

[Kernaljonboy]

I took out my Huskyliners to clean them off and noticed that there was moisture under the passenger side floor mat. Upon further inspection I found that the plastic housing for the HVAC had a crack in it where it drains the condensation from the air conditioner. I was wondering if anyone else had the same problem and if they got it fixed was it covered by warranty. I plan on stopping by the dealership later this week to see what they have to say about it.

 

[RedZilla]

That's a condensate leak from the AC system and should not do that. It needs to be addressed as a warranty repair.

Edit: There's a drain tube on the bottom of the AC unit that drains condensate to the ground outside the truck. This may be disconnected or the AC unit may not be sealed properly.

 

[Kernaljonboy]

That's a condensate leak from the AC system and should not do that. It needs to be addressed as a warranty repair.

Edit: There's a drain tube on the bottom of the AC unit that drains condensate to the ground outside the truck. This may be disconnected or the AC unit may not be sealed properly.

I know about the drain tube that is connected to it and that isn’t the problem. The housing is broken. Here are some better photos.

 

[BroncOh]

Did Ford put that in the path of a foot being able to kick it and break it?

I hope pulling the dash isn't necessary.

 

[Dutch061]

Sorry to be the bearer of bad news, the dash must come out to remove the HVAC housing. The entire HVAC housing will need to be replaced.

BTW, I don't believe there is a hose installed anymore in most applications anyway.

 

[Grabber]

Looks liked it got banged sometime during manufacturing process. Its a big job, but hopefully should be a straight forward repair.