Leak Into Passenger Floorboard

[ARDU]

Just wanted to report my leak experience:

2023 Hybrid Maverick XLT delivered April 2023 (built March 2023)
9800 miles. Garage kept at home. Parked outside during days at work.
No recalls performed, yet.

Noticed a musty smell in early August 2024 (rained a lot in June and July). Pulled up my factory Maverick floor liner (not carpet ones) and the black carpet was discolored with white mold and the carpet and pad were soaked. Called dealer for appointment. Had to wait a week and drive with windows down as my throat was sore from breathing in the mold spores with air conditioner running. I explained to the service dept. what others on this forum have found that the leak is at the outside air box under the cowl. The carpet needed replaced, too. I was given a loaner from dealer upon request. 2 weeks later contacted stating my truck was ready for pickup today, 9/9/2024. Service guy stated the leak was the air box outside under the cowl and the flashing was not installed correctly. This let water into the air box, soaking the cabin air filter then into the truck floor board. They installed new flashing, air filter, and new carpet. Smells a lot better. Was told I would be able to get a printout of actual work done once the "warranty" was closed by a different office next week. The dash did not have to be removed to fix.

So if anyone out there has a Maverick built around the same time mine was, you probably have a leak too.

UPDATE 11/19/2024: I added the vehicle report that shows the work that was done and part numbers.

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[clearviewx]

Thanks for sharing....

 

[mykoleary]

So if anyone out there has a Maverick built around the same time mine was, you probably have a leak too.

For those like me that didn't know when your truck was built:

https://www.ford.com/support/how-to.../how-do-i-find-the-build-date-for-my-vehicle/

 

[MavTime]

I don't smell anything or feel moisture under the mat. But the AC does smell a little musty, so I try to dry it out before shutting it off, I need to make sure my drain is working on it.

 

[Elduchey]

I cant believe Ford has not fixed this at the production level yet. My 22 was torn apart multiple times for almost three years before they found the leak. I thought Quality was job 1?

 

[NeilsTruck]

I have a question about the dates on your post. I have a 23 hybrid built in March of 23 and delivered at the end of March of 23. I also keep it garaged and live in a desert climate with little rain so although my carpet feels dry so is everything around here! Would you repost the build date. Thank you!

 

[Toddman45]

Is this an issue for all Mavericks, or just Mavericks that were built on and between a certain date and time?

Also could someone post a picture pointing out the area of where the leak or water intrudes the cab at? Thank you

 

[ARDU]

I have a question about the dates on your post. I have a 23 hybrid built in March of 23 and delivered at the end of March of 23. I also keep it garaged and live in a desert climate with little rain so although my carpet feels dry so is everything around here! Would you repost the build date. Thank you!

Not sure why I put wrong date. It is corrected. Build was March 2023 and delivered April 2023. My window sticker is dated 03/27/2023.

 

[NeilsTruck]

Thanks for the update, I knew either the model year or the build date had to be a misprint, my window sticker says 3/2/23 so I will watch it carefully after it’s out in the rain or a long wash. Enjoy your truck!

 

[bgn]

I cant believe Ford has not fixed this at the production level yet. My 22 was torn apart multiple times for almost three years before they found the leak. I thought Quality was job 1?

Yes, Job 1 has been quality at Ford since the 1980s. And they have done such a good job at Job 1 that they continue to be one of the most recalled brands in America, if not Number 1, year after year. It's not easy having a terrible quality culture, but someone's gotta do it.

 

[bgn]

Is this an issue for all Mavericks, or just Mavericks that were built on and between a certain date and time?

Also could someone post a picture pointing out the area of where the leak or water intrudes the cab at? Thank you

Won't comment on what trucks are affected, because I haven't been following this issue specifically, but I will share with you that the issue is an incorrectly installed or completely missing plastic piece under the windshield cowling. As far as I'm aware, there's no way to inspect it outside of removing the cowling. My October 2021 build does not have this issue.

 

[ARDU]

Won't comment on what trucks are affected, because I haven't been following this issue specifically, but I will share with you that the issue is an incorrectly installed or completely missing plastic piece under the windshield cowling. As far as I'm aware, there's no way to inspect it outside of removing the cowling. My October 2021 build does not have this issue.

Yep, that is basically what the service rep at the dealership said. Said the "flashing" was installed incorrectly and that lets water leak into the air box. The cabin air filter gets soaked, then water leaks down into the passenger floorboard. They put a new "flashing" = the plastic piece on mine to fix the problem. There will be a lot of rain here tomorrow -- thanks Francine. So time will tell if it is fixed. They have 3 chances to fix it in my state for lemon law.

 

[NeilsTruck]

ARDU, I cannot thank you enough! I had some time today and removed the cabin air filter and on the bottom side it is light gray which I am sure is the start of black mold. If you remember I live in a desert climate and it may have been years before it got bad enough to smell like yours did, perhaps beyond the warranty period ! I am so disappointed in Ford for not telling us know to at the very least to pull and inspect the cabin filter as this a health hazard ! I agree with you that anyone with a hybrid built in the spring of 23 should inspect their cabin filter. I believe it should be white on the bottom. Incidentally the owners manual is missing a step to remove the glovebox to access the cabin filter. Thank goodness for YouTube! If not for your original post I may have been left with a future expensive repair bill! Apparently quality at Ford is now JOB NONE !!!

 

[TN2025]

Just wanted to report my leak experience:

2023 Hybrid Maverick XLT delivered April 2023 (built March 2023)
9800 miles. Garage kept at home. Parked outside during days at work.
No recalls performed, yet.

Noticed a musty smell in early August 2024 (rained a lot in June and July). Pulled up my factory Maverick floor liner (not carpet ones) and the black carpet was discolored with white mold and the carpet and pad were soaked. Called dealer for appointment. Had to wait a week and drive with windows down as my throat was sore from breathing in the mold spores with air conditioner running. I explained to the service dept. what others on this forum have found that the leak is at the outside air box under the cowl. The carpet needed replaced, too. I was given a loaner from dealer upon request. 2 weeks later contacted stating my truck was ready for pickup today, 9/9/2024. Service guy stated the leak was the air box outside under the cowl and the flashing was not installed correctly. This let water into the air box, soaking the cabin air filter then into the truck floor board. They installed new flashing, air filter, and new carpet. Smells a lot better. Was told I would be able to get a printout of actual work done once the "warranty" was closed by a different office next week. The dash did not have to be removed to fix.

So if anyone out there has a Maverick built around the same time mine was, you probably have a leak too.

UPDATE 11/19/2024: I added the vehicle report that shows the work that was done and part numbers.

Question has anybody had this problem where it’s not under warranty how much they charged or nobody in Tennessee in Smyrna Murfreesboro or Franklin that might be able to help fix it for a better price?

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