[obermd]

Dealer texted that they found the leak behind the black plate. They say that it is a body seam. It is at their body shop and will be repaired tomorrow. They don't seem too interested in looking into if there is an underlying cause with the HVAC drainage so hopefully this isn't just a bandaid that will cause bigger issues down the line.

I'll report back if any continuation of the issue.

If its truly water getting in there is no HVAC leak as the HVAC system doesn't use water. What's getting in is condensation.

 

[obermd]

UPDATE:

Picked up today from the dealer after body shop repaired the leaking seam. Drove the long way home - surface roads, hilly - with AC on full blast entire way. Dry. Seems that they've at least fixed the water intrusion issue, for now.

Asked them about an underlying issue with condensate not draining properly and was pretty much brushed off. Looks like this is as far as I will get for now.

My guess is the condensate is on the outside of the pipes so there is really nothing they can do to drain it elsewhere.

 

[obermd]

I just saw this on a Facebook post about this issue, but haven't yet confirmed the accuracy. This is the first I've heard of an actual TSB about this:

There was a service bulletin about this that was released on Aug 6th. #25-NA-149

The issue appears to be a A/C drain tube in the firewall that was not seated/connected properly during production.

And combine this with a seam not properly sealed you get a leak.

 

[obermd]

Well the "fix" was a complete failure. I haven't even run the AC yet and I already see some water leaking through the caulk stuff, and the caulk is not setting due to water mixing in with it. I guess I'll be calling the dealer again on Monday. I'm not happy.

This tells me they need to clean and dry that area before applying the calk. This is a standard requirement when applying any sealant calk and the fact that it wasn't setting up properly should have told the tech that he hadn't done the job right.