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Just driving the 03 exp I purchased in GA back to CT. My wife's feet are getting wet with the A/C running. The condensate seems to be dripping fine below the truck. It looks like the black plastic housing over her feet is just getting so cold that water condenses on the outside and drips. Any solution to this?
The fix is to put the TSB rubber elbow on the drain outlet. At highway speeds air pressure under the hood causes the condensation drain to back-flow around the outlet and into the insulation. Ford cut the drain outlet nipple too short and they fixed it in later years. Here's a post on another forum discussing it: Expedition AC drain elbow installation. I'm in south Florida, and as humid as it is down here, with normal drainage I get no condensation buildup while using the AC. The bottom of the housing is dry.