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I have an 81 F100 Custom. The cowl has been leaking for some time now & has caused the floor pan to rust out on the drivers side. I would like to fix this leak so that I can replace the floor pan with out the worry of more rain or other water getting into the cab of the truck.
One of the most common causes for a leak is the cowl drain is clogged. The best way to access the drain is to remove the front fender. You will be amazed on how much crap accumulates in the drain from bugs, to leaves, pine needles and that is actually great mulch material.
Find the leak first. try a garden hose and running water into the cowl. Like I said my $$$ is on the cowl drains.
Two fullsize trucks I have had, had the following problem. The water would fill up the bottom of the max air door box down on the passenger footwell and then spill over soaking the floor. Reason, water goes into the cowl and runs down the engine side of the fire wall. This allows water to migrate into the ac heater box, and then into the truck. There is a thick foam water seal under your cowl that I am sure is brittle and falling appart. Replace it. I went the cheap route and siliconed a water shield above the heater hoses about 8 inches wide to divert water away from the ac heater box.
Bronco scott... yes the water is routed that way with soft rubber tubes. This gentlemans problem is on the drivers side and the AC and heater core is on the passenger side.
Back to my original thought.... clean out the drain tubes.
If your cowl gets leaves and such in it on a regular basis, you can pick up a couple of those acces plates from a salvage yard, cut out the very bottom of the firewall and cover the holes with a putty type sealer and attach with screws.
Now you can run water in the cowl and let th trash flow out of the access holes.
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