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Just bought an '02 Explorer last month and have noticed a musty smell inside. Air is cold and I have condensate dripping under the truck, however it is dripping right off of the bell housing. While playing around under the dash, I noticed that some of the unpainted parts under the seat and under the dash have light surface rust.
Where is the drain for the evaporator? This might sound crazy, but is it possible that it is clogged and the case is holding water which is giving the interior a high humidity rate that could lead to the surface rust under the dash and seat? Also, since it is dripping (not where I think it should), is it possible that the drain is clogged and it is filling up the case and there is a secondary or overflow drain? At any rate, it looks like a pain to get to on the 4.6.
Its possible to be clogged up but if the rate of drainage while running is good then not likely creating the problems you describe. You may however have a windshield leaking and allowing excess moisture under the dash and on to the carpeting. However it is rather normal for unpainted surfaces to get some rusting from general humidity conditions over time. If its heavy rust with pooling spots then I would be looking into a windshield leaking scenario. Musty smell is a very common problem, especially during abnormally hot summers when Recirculated AC is used almost entirely. You can purchase evaporator disinfectants to kill most of the bacteria that forms.
Last edited by HomerWinzlow; Sep 22, 2003 at 09:19 PM.
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