Excessive heat on front passenger floorboard

[drpaul]

I'm the new owner to a 2012 Expedition Limited 4X4 with 46,000 miles on it. Last week, the front floorboard carpet was soaking wet? We did have a rainstorm the night before, but it happened again this weekend without any rain. Any ideas?
Then, on a 200 mile roadtrip this same weekend, the front passenger floorboard was literally burning hot! About a 1 1/2 foot area that was not just warm to the touch, but HOT? My initial thought was a bad catalytic converter under the truck. But I don't believe in co-incidences and am wondering if there is a relationship to the wet floor board carpets in the same area?
Thanks for all you help and advice!

 

[01yellerCobra]

The wetness might be a heater core issue. Or the A/C not draining correctly. The cat is right by the floor board. Maybe make sure the heat shield is in place.

 

[drpaul]

I'll get underneath it tonight and look for the AC condensation line as well as heat shield for the catalytic converter. Thanks

 

[drpaul]

So it appears that the heat shields are in place under the truck and over the cat converter. I also see water condensation from the AC unit coming out from under the truck. So I pulled off the plastic at the door frame and by passenger footrest so that I could pull the carpet up, and there is actually water pooling on the floorboard. It appears wet further up the firewall toward the front of the car, and I suspect that this may be more the source with water just finding its lowest point? What would be symptoms of a heater core leaking? Any ideas and insights are helpful as I will first try to track this one down before taking it to the dealer as it is just 2K over being out of warranty....grrrrr Thanks!!

 

[01yellerCobra]

Usually if it's the heater core it'll smell like coolant inside. If it doesn't smell like coolant then you'll have to follow it up as far as you can. It might be the windshield leaking.

 

[Bedrck47]

also check you rear wiper washer tubing I'm not sure how they run the washer line for your year but the first Gen's had the line running behind the right side kick panel.

If it a coolant leak you should be able to see if your coolant level is dropping

 

[BIG GREEN FORD]

Has it rained lately ?

 

[GaryH2]

You didn't say if your Expy has a sunroof. If it does, it could be that the drains are mucked up.

If you search the forums you can also find info on AC condensation dripping into the passenger footwells. If I recall correctly, the Navis have some additional parts to alleviate the issue. As mere Ford owners, we don't rate.

I know some of the older Expys (Gen I) had an issue with the drain around the windshield where it would leak into the fuses and cause issues. The Bro's ex had one with that problem.

As far as the heat, I would guess that the wet carpet made the floor feel warmer, but that's only a guess.

 

[drpaul]

No smell of coolant and water accumulates even with no rain. I'm going with the AC condenser line being plugged for now. Will keep ya all informed about the water issue. The heat was excessive in the same area. My passengers have to lift their feet off the floor board, it gets that hot. More poking and prodding to be done this weekend to look into the state of the CAT converter.
Thanks so far!

 

[metaldrgn]

I'm the new owner to a 2012 Expedition Limited 4X4 with 46,000 miles on it. Last week, the front floorboard carpet was soaking wet? We did have a rainstorm the night before, but it happened again this weekend without any rain. Any ideas?
Then, on a 200 mile roadtrip this same weekend, the front passenger floorboard was literally burning hot! About a 1 1/2 foot area that was not just warm to the touch, but HOT? My initial thought was a bad catalytic converter under the truck. But I don't believe in co-incidences and am wondering if there is a relationship to the wet floor board carpets in the same area?
Thanks for all you help and advice!

Yes I think they are related. Water transfers heat better than air (if you've ever used a wet pot holder you'll see proof of this) so either the water is also leaking through the floorboard onto the heat shield or just the water on the floorboard is conducting heat. I could be wrong, but you've already seen that the heat shields appear good. I would solve the water leaking problem first and then see if you still have a heat problem. How rusty is it underneath the vehicle?

 

[JUST4FUN]

The cat will still be covered by the warranty . do you have a sunroof

 

[BIG GREEN FORD]

Is your cat normal in color? Same color as driver side?

 

[drpaul]

Just spend some quality time under the truck with front end lifted up about a foot. With the AC on full blast, I could see water slowly (very) dripping out from under the truck near the passenger firewall. BUT...no hose to be found and once I really moved around to catch this area from all angles, I can see that its dripping from the silver heat/sound barrier material which separates the engine compartment from passenger area. Once inside the truck, this is the same area where water is coming into the passenger compartment as well, and it drips down into the passenger footwel/carpets.
So it certainly appears that the AC condenser is not draining properly! Any clues as to where this drain hose is supposed to be coming from? I truly can't seem to find a possible origin point?
Metaldrgn...yes...way more rust in this same area than I would expect from a 2012.
Biggreenford...same color cats on both sides...maybe slightly more rust on passenger side. I put my IR heat gun to both and they appear even (around 350), BUT the area where the heatshield is above them, has a higher temp above the passenger side. Maybe due to more water accumulating there or rust?
Any ways...I need to get to the water not draining from AC system...it seems to be the culprit of both excessive rust and heat near the passenger floorboards.
Any advice here is great! THANKS

 

[metaldrgn]

This view should help but I can't see it well because it doesn't want to open on my phone.

2012 Ford Expeditionhis A/C Evaporator Case Drain Hose | FordParts.com

 

[metaldrgn]

Here we go. It's P/N 19K592

 

[drpaul]

That's kinda funny metaldrgn. You can't see ANY of these parts on the vehicle...its all under the dash/behind the glovebox/tucked away in dark places. Either way...I took off the front passenger wheel, removed the mudguards, and still can't really see any drain hose. I can see the layer of heat shield and black plastic piece where the condensation comes from. So tomorrow I will stop at Ford and pick up both this elbow piece (F3LY-6A614-A) they have available to try and prevent the drain line from closing down where it now supposedly bends and a new drain line (7L1Z-19K592-A)to extend it past all these layers of insulation and heat shield so that it can drain properly.
I'm still amazed that this hasn't happened to more Expedition owners, or they they all just go back to Ford to fix it and pay their mechanics $120 an hour?
I'll let ya know how it turns out! Hopefully no more indoor Jacuzzi on my carpets floorboards!

 

[metaldrgn]

Did you think you wouldn't have to take some stuff off to see it? There should be a kick panel that can be removed and you may be able to see some of those parts. That picture
should give you an idea where to look. Maybe check YouTube.

Good luck.