Water Leak

[JME42]

Well for the few months and roughly 1700 miles I've owned my 2023 XLT, FX4, Maverick I have been hearing a liquid gurgling noise after a rain with the vehicle sitting still and the climate control fan on. Didn't think about it too much until this weekend I gave the truck its first wash and the passenger floor mat and carpet were wet. Water looks like it came in through the cowl intake area. It soaked through the cabin filter and was running out of the fan housing below the cabin filter. Was also running out to the left of the housing near the foot vent. I pulled the carpet up and dried it out over the weekend.

I've read a few threads discussing possible cowl fitment issues. I don't see any fitment issues right off the bat. I also have the windshield rattle that a few folks have mentioned. Sounds like that is unrelated and likely the alignment dowls on the passenger upper A pillar. Dropped the truck off at the dealership today to look into the leak. The service advisor thinks this is a windshield issue. Also mentioned the windshield rattle but mentioned my primary concern is the large water leak. Noticed today as well that the AC is starting to get a smell to it. Hope i caught this early enough to not have serious mold/mildew issues.

Has anyone experienced this recently with their truck that may have some insight?

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[JME42]

Adding pictures of areas with water for reference.

 

[JME42]

Minor update - dealer said they confirmed the leak today. Going to pull the cowl off in the morning to inspect further.

 

[801Maverick801]

Water right above that fuse panel, yikes...

 

[JME42]

Water right above that fuse panel, yikes...

Yep, and the blower for the AC. Will be interesting to see if any electrical issues come out of this.

 

[Elduchey]

Thanks for sharing this info. My Mavs been in the shop for a few weeks now trying to locate the leak so I'll forward this over to them.

Let us know how yours works out.

 

[JME42]

Thanks for sharing this info. My Mavs been in the shop for a few weeks now trying to locate the leak so I'll forward this over to them.

Let us know how yours works out.

Service advisor said they pulled the cowl today and confirmed the leak was from the cowl into the AC fresh air intake and onto the cabin air filter. I previously verified that myself so they drew the same conclusion as me. Said they ordered a part to fix it... couldn't confirm if my truck was missing the part or if it was improperly installed/damaged. Will update again tomorrow.

 

[Elduchey]

Service advisor said they pulled the cowl today and confirmed the leak was from the cowl into the AC fresh air intake and onto the cabin air filter. I previously verified that myself so they drew the same conclusion as me. Said they ordered a part to fix it... couldn't confirm if my truck was missing the part or if it was improperly installed/damaged. Will update again tomorrow.

Just got mine back and they still couldn't find the source of the leak so I guess it's up to me to trouble shoot until Ford actually comes clean on the issue. We are suppose to get rain tomorrow so I'll be sure to run the AC and check the cabin air filter.
This is gonna be my third time at the shop for this so if they cant get it right I'm gonna be tempted to pull the lemon law out on em.

 

[JME42]

Just got mine back and they still couldn't find the source of the leak so I guess it's up to me to trouble shoot until Ford actually comes clean on the issue. We are suppose to get rain tomorrow so I'll be sure to run the AC and check the cabin air filter.
This is gonna be my third time at the shop for this so if they cant get it right I'm gonna be tempted to pull the lemon law out on em.

Definitely check to see if the cabin filter is wet. If so your leak cause is likely the same as mine. Will report back with details on the fix and if the fix works.

 

[Elduchey]

Definitely check to see if the cabin filter is wet. If so your leak cause is likely the same as mine. Will report back with details on the fix and if the fix works.

You gonna push them for new carpet and padding? Mine smells like a locker room right now and I'm not gonna back down until they replace that rug.

 

[JME42]

You gonna push them for new carpet and padding? Mine smells like a locker room right now and I'm not gonna back down until they replace that rug.

If it ends up smelling I will. I dried it out immediately so I hope that prevented any issues.

 

[Ford Motor Company]

Well for the few months and roughly 1700 miles I've owned my 2023 XLT, FX4, Maverick I have been hearing a liquid gurgling noise after a rain with the vehicle sitting still and the climate control fan on. Didn't think about it too much until this weekend I gave the truck its first wash and the passenger floor mat and carpet were wet. Water looks like it came in through the cowl intake area. It soaked through the cabin filter and was running out of the fan housing below the cabin filter. Was also running out to the left of the housing near the foot vent. I pulled the carpet up and dried it out over the weekend.

I've read a few threads discussing possible cowl fitment issues. I don't see any fitment issues right off the bat. I also have the windshield rattle that a few folks have mentioned. Sounds like that is unrelated and likely the alignment dowls on the passenger upper A pillar. Dropped the truck off at the dealership today to look into the leak. The service advisor thinks this is a windshield issue. Also mentioned the windshield rattle but mentioned my primary concern is the large water leak. Noticed today as well that the AC is starting to get a smell to it. Hope i caught this early enough to not have serious mold/mildew issues.

Has anyone experienced this recently with their truck that may have some insight?

Hi there, I'd be happy to look into your Maverick concerns on my end. Will you send us a message with your VIN and dealership info? I can look into things on my end.

 

[Xbbqpitmaster]

Be sure and keep a copy of the problem, service record etc. just in case later down the road you start having electrical problems caused by the water on the electrical components which could cause corrosion etc. this advice was given to me by a Ford salesman when I had a issue years ago… luckily I did not have any issues for several years, but it did start having intermittent check engine light that came and went and could never be diagnosed as to why….

 

[Elduchey]

Just had a brief drive in the rain and saw some moisture (not as much as yours) in the upper left hand side of the cabin air filter box. The filter itself is not wet to the touch but I was only in the rain for fifteen minutes or so.
We had a ton of rain over the winter in California that I had to drive in daily so it would make sense that if this is a slow leak that only happens if you have the fresh air going for a few days/week of commuting in the rain before you would see any significant moisture coming through the system.
How many days were you driving in the rain before you noticed the problem?

 

[JME42]

Be sure and keep a copy of the problem, service record etc. just in case later down the road you start having electrical problems caused by the water on the electrical components which could cause corrosion etc. this advice was given to me by a Ford salesman when I had a issue years ago… luckily I did not have any issues for several years, but it did start having intermittent check engine light that came and went and could never be diagnosed as to why….

For sure, lots of electrical components in the area got wet.

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