That goo used to seal the leak looks like the same stuff the factory uses in manufacture. (polybutylene?) That stuff will probably outlast the body panels it is sealing.
My Ford dealership had the water leak specialist go over my new 2024 Musty smelling Mav today and found no water leaks. He was able to access the seam affecting Maui, via the glove box removal and it was clean as new with no apparent leak. He pulled back the passenger side carpet and everything is clean as new. All outside intake air vents showed no clogs.
So I am happy that my Mav is not completely taken apart like Maui, but concerned that I am now on a wait-and-see (or wait-and-smell) holding pattern.
With the better weather I will continue to “open window” vent, and will update if more info comes forth.
Probably mildew/bacteria in the AC system(coil). I had a Chevy truck that had it. I used the foam cleaners that injected up through the drain line. Lasts for a few months. Don’t use recirculating air al the time.
It could also be some garbage recycled material the truck is built with inside breaking down. We used to get cardboard boxes holding flatscreen TVs at work from an Asian country that smelled like human waste when exposed to the sun/heat. Again some recycled material I’m sure.
Sounds maybe like the Stinky Sock Syndrome that can happen in hvac systems, I had a evaporator coil go out in my home unit several years ago, technician replaced it with a new one, didn’t take long for the stink started. Called the tech back out, the manufacturer replaced with another new one, issue resolved. Tech said the recycled aluminum used in making them was the cause, but mold/mildew in the system it also a cause, but my unit check free of that. Maybe that can be related to your issue?
The odor in mine is a chemical smell and it burns my eyes and sticks to my clothes. Got my Mav in March of 2023 and the smell is still there. I thought it was the new car smell but it's not. It's very chemically smelling. I will pull the filter and glove box to see if that's the source. Glad I found this post. Thanks!!