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'03 'Gator, mildew smell as of recently. There is also staining around the headliner at the rear over the cargo compartment. It's been there since I bought the car few months ago but the car just started smelling. Also no water or wetness present at all anywhere. Sprayed the car down with a hose to look for leaks and can't see anything anywhere, I almost think I don't have a leak. FYI, the car doesn't have a sunroof either.
Only other thing is the rear vent HVAC actuator was broke which I replaced today. Could this cause heavy condensation in the system/headliner and caused the smell?
I'm at a loss. The amount of niggling little BS issues this thing has is beyond frustrating.
With the A/C running do you see a good drain flow from the front evaporator drain? Do you feel any wetness in the carpet under the front passenger foot rest area? The wet carpet is a common problem with the '03-'06 Expy, Navs, F150s because there was no evap drain elbow installed from the factory. The drain water got blown back against the firewall opening and into the carpet padding, caused a lot of mildew smell complaints. Other than that is there any pin hole rust spots in the roof channels ? That's another common problem. Water sits in those channels and causes pin holes and corrosion/rust in the roof. If that sagging area in the rear of your headliner is more than just the cloth coming loose, like the backing cardboard is also sagging, I would look for rust in the roof above that area. Fix it, and replace the headliner.