Alright, so I've done some extensive searching on this forum for leak problems and they're solutions that could help my problem, and so far have not come up with a solution. The common problems so far that I have found are as follows:
Clogged cowl/heater air intake drain
Cowl to windshield gasket
Failed windshield gasket
Leaking from the air conditioning drain in firewall
Cracked or broken heater core
Leaking in from the doors
My jeep has a leak that accumulates about 1" of water in the passenger side floor after a moderate to heavy rain, and while driving, occasionally I will get the dreaded dripping on the clutch foot.
I have checked the cowl drain, and it drains very well and is very clean inside.
I have put silicon sealant to seal the cowl to windshield gasket from the outside.
Around 2 years ago I replaced all the hardtop gaskets and while the top was off I sealed the factory soft top holes at the top of the windshield frame
It is definitely NOT coolant, so it is not the heater core or associated tubing.
I took the heater/air intake off recently and found that the drain has a slight lip(1/16" to 1/8") that may be the cause of the dripping on feet while turning. Will grind this down to fix this. Cannot be the cause of the passenger floor puddling due to the good drainage otherwise
I have not gotten the windshield gasket replaced, however it seems unlikely that the large amount of water that comes into the passenger side floor is from this.
The door weatherstripping has been replaced within 2 years, and it does not seem to be leaking in from around the door.
Any help or suggestions as to what may be causing this large amount of unwanted water to enter my jeep would be greatly appreciated.
Apologies for the long-winded post.
I have a 1991 Jeep Wrangler Sahara 4.0 Liter Inline Six with 147,000 miles, with an aftermarket hardtop installed with halfdoors.