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Unread 01-01-2008, 10:00 AM   #1
PunisherZJ
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Repairing a Clogged AC Drain

I know this topic has been covered, I actually learned how to do it from this site. One thing I could not find is any actual photos of the process. I took some photos of the job to help others with the same problem.

I had moisture on the passenger side floor pan of my 97 GC 5.2L. It didn't feel or smell like antifreeze so I eliminated the heater core as an issue. I learned from members of Jeepforum that it was possibly a clogged AC drain. Using the recommendations from others I started the job.

Locate the HVAC box drain by pulling the carpet back on the passenger side. Its a round piece that goes into the firewall.


Drill a 1/4 inch hole into drain



Blow out with air


I wasn't able to locate a rubber plug to plug the hole but I did find find a plastic fastener for interior trim. Once I can locate a rubber plug to fit, I plan on changing it out.


Applied a bit of Goop to help seal


Installed plug then cover surface with more Goop to ensure a good seal


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Unread 01-01-2008, 12:27 PM   #2
Dillonzj
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Quote:
Originally Posted by PunisherZJ
I know this topic has been covered, I actually learned how to do it from this site. One thing I could not find is any actual photos of the process. I took some photos of the job to help others with the same problem.

I had moisture on the passenger side floor pan of my 97 GC 5.2L. It didn't feel or smell like antifreeze so I eliminated the heater core as an issue. I learned from members of Jeepforum that it was possibly a clogged AC drain. Using the recommendations from others I started the job.

Locate the HVAC box drain by pulling the carpet back on the passenger side. Its a round piece that goes into the firewall.


Drill a 1/4 inch hole into drain



Blow out with air


I wasn't able to locate a rubber plug to plug the hole but I did find find a plastic fastener for interior trim. Once I can locate a rubber plug to fit, I plan on changing it out.


Applied a bit of Goop to help seal


Installed plug then cover surface with more Goop to ensure a good seal
nice pictures
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98' JEEP GRAND CHEROKEE LIMITED 5.9
149k 5.9L v8 White

Crane Cam shaft and Crane, Roller Rockers, bored .030 over, edelbrock performer heads, M1 Intake manifold, Fasstman throttle body, magnacore wires, platinum plugs, K&N FIPK, dough thorley headers,3" high flow cat, 3" magnaflow mandrel bent exhaust, SCT tuned

***future mods -5.5 IRO LA - KOR sliders -KOR roof rack -

SOLD-
95' JEEP GRAND CHEROKEE LIMITED
188k 5.2L v8 White 98 ZJ rims

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...we all know they empty our pockets...yet they fill our hearts...


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Unread 01-01-2008, 12:30 PM   #3
PunisherZJ
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Quote:
Originally Posted by Dillonzj
nice pictures
Thanks! How did you get them to open on the thread? I used the img tags but it just showed the link.
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Unread 01-01-2008, 12:33 PM   #4
Darthteddy
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Must have 50 posts and be here a month to have pictures show up. Great write up. If mine ever clogs, now ill know what to do.
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Unread 01-01-2008, 12:35 PM   #5
PunisherZJ
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Quote:
Originally Posted by Darthteddy
Must have 50 posts and be here a month to have pictures show up. Great write up. If mine ever clogs, now ill know what to do.
Oh okThat makes since. I just went out and changed that plug to a rubber plug. I'll update the thread in a bit.
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Unread 01-01-2008, 04:11 PM   #6
PunisherZJ
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As I mentioned above, I changed my mind about using that plastic trim fastener for a plug. I went to Advanced Auto Parts and grabbed a set of universal plugs:


Found one that somewhat fit but had to shave it a bit to make it fit tight and go all the way in the hole:



Added Goop to seal it...all done
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Unread 01-01-2008, 05:47 PM   #7
Dillonzj
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Quote:
Originally Posted by PunisherZJ
As I mentioned above, I changed my mind about using that plastic trim fastener for a plug. I went to Advanced Auto Parts and grabbed a set of universal plugs:


Found one that somewhat fit but had to shave it a bit to make it fit tight and go all the way in the hole:



Added Goop to seal it...all done
pictures!
__________________
98' JEEP GRAND CHEROKEE LIMITED 5.9
149k 5.9L v8 White

Crane Cam shaft and Crane, Roller Rockers, bored .030 over, edelbrock performer heads, M1 Intake manifold, Fasstman throttle body, magnacore wires, platinum plugs, K&N FIPK, dough thorley headers,3" high flow cat, 3" magnaflow mandrel bent exhaust, SCT tuned

***future mods -5.5 IRO LA - KOR sliders -KOR roof rack -

SOLD-
95' JEEP GRAND CHEROKEE LIMITED
188k 5.2L v8 White 98 ZJ rims

Quote:
Originally Posted by nashmd454 View Post
...we all know they empty our pockets...yet they fill our hearts...


MY BUILD THREAD
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Unread 01-01-2008, 06:15 PM   #8
Turbonut
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Great writeup if the drain is clogged, but many times the seal at the firewall deteriorates and allows water to run back into the comparment when the Jeep is uphill.
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Unread 01-01-2008, 06:44 PM   #9
PunisherZJ
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Quote:
Originally Posted by Dillonzj
pictures!
Thanks!
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Unread 01-01-2008, 06:46 PM   #10
PunisherZJ
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Quote:
Originally Posted by Turbonut
Great writeup if the drain is clogged, but many times the seal at the firewall deteriorates and allows water to run back into the comparment when the Jeep is uphill.
I'm hoping this was the problem. Guess I'll know in a few days. I'll look into that if I still have an issue.
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Unread 01-02-2008, 06:38 AM   #11
georged
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Just looked at the picture of the package of assorted bumpers. It looks like one of them would be perfect for the gas door bumpers that seem to disppear.
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Unread 01-02-2008, 06:43 AM   #12
coonash
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Quote:
Originally Posted by Turbonut
Great writeup if the drain is clogged, but many times the seal at the firewall deteriorates and allows water to run back into the comparment when the Jeep is uphill.
that is my problem.
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Unread 01-02-2008, 10:27 AM   #13
Turbonut
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Quote:
Originally Posted by coonash
that is my problem.
Well, your PM's are filled, but you need to cut a 2" x 3" access hole behond the right front wheel. Then attach either a curved hose to the drain, or since I had a large plastic washer in the garage, I applied silicone around the tube at the firewall and slid the washer over into the silicone and against the firewall. Covered 2 x 3 hole with sheet metal and undercoating. Never leaked again.
I did this back in 1998 and was fine when the Jeep was sold in 2003.
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Unread 01-02-2008, 11:42 AM   #14
FPKites
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Wonderful writeup! Needs to be sent to the tech articles section!
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Best mod you'll ever do on ANY vehicle!!!!

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Unread 01-04-2008, 06:36 PM   #15
swataz
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I have the same problem with no AC drainage, and this is all great info and I will attempt it soon.

My question is this -- is there NO way to access the drain tube on the engine side of the firewall?
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