Hello,
I've used the search function, and all I get is information on 2003-2007 Expy/Gators regarding a/c condensate soaking the passenger floor board. Is this a common issue for Gen1 Expy/Gator as well?

Don't really notice it much driving around town, but took it on a short road trip yesterday and the passenger floorboard was soaked. No color, and no odor, so I don't believe a heater core is the problem. Where, exactly, on this truck would one find the condensate drain line to check it?
Thanks in advance.

 

I'm not sure exactly where it is, but when you park with the AC on if it is working properly you should see drips underneath between the passenger side front tire and the front door. If you have a sunroof you should also check the drains to make sure they are working.

 

I do see water hit the ground when the ac is on and the truck is parked. Like I said, only an issue when driving on the highway it seems. Sounds like the problem I have seen for the Gen 2 Expy/Gators, but haven't seen anything similar for Gen 1.

 

I have a 2000 expy that used to have a wet passenger floor board.
the problem turned out to be the rear windshield washer hose that runs along the fuel pump reset switch, there was a coupling that had come apart. it was a easy fix.

 

If you are seeing water, then you should be able to follow that up to the drain. Maybe it is partially blocked.

 

I had the same problem!

 

Ok, so still haven't found the issue with the wet floorboards (no time to look at it yet), and now that we've had a couple healthy rains the last couple days, I've noticed the problem is worse. Looks like I've got myself two water sources. One related to A/C and one related to rain intrusion. Looks like I'll be removing the cowl and hoping the drains are plugged and it's not a bad windshield seal. Didn't see any water around the door frame, so I don't think it's the door seals that are leaking. Good times. Diagnostic codes are so much nicer to deal with than these look & see type problems.

 

I will try again, do you have a sunroof?

 

No sunroof

 

Could be a leaking windshield.

 

Did you check the windshield hose advice above? You don't mention checking this. If its been raining, I would think you would be using your windshield washers when you followed other vehicles with splatter.
Kerim1, reps to you.

 

I had similar issue and it turned out to be a simple seal problem. It was strange how rain went through that hole into passenger side floor.

https://www.ford-trucks.com/forums/1...ide-floor.html

 

I haven't had the opportunity to check much of anything yet, hope to get some time this weekend. I have not been using my washer much at all, and my rear washer is still working, so I don't think that is the problem. I'll dry out the vehicle, then drive it for a bit with no washer use at all, and the carpet is wet. I am driving today with no AC to see if that can be ruled out.

There was a significant increase in floor wetness after the heavy rain though, so I still think I'm looking at two potential issues.

Thanks again all for the help. Hopefully I'll have something useful to report after the weekend.

 

I plan to inspect all the penetrations I can reasonably get to this weekend. Be great if a tube of high temp silicone does the trick.

 

Make sure you seal everything! I will be doing that too! Let me know how it works out for you!