NHTSA Complaint #10466436 — 2002 FORD TAURUS

I HAVE A 2002 TAURUS WHERE THE PASSENGER SIDE FLOOR WAS GETTING SOPPING WET WHEN THE A/C WAS USED. I DETERMINED THE PROBLEM WAS BACK-FLOW THROUGH THE HIGH DENSITY FOAM SEAL THAT SURROUNDS THE DRAIN SPOUT. THE DRAIN SPOUT GOES THROUGH A HOLE IN THE FIREWALL, AND BLACK HIGH DENSITY FOAM SEALS BETWEEN THE HOLE AND THE EVAPORATOR DRAIN SPOUT. BECAUSE THE DRAIN SPOUT IS MORE OR LESS HORIZONTAL, INSTEAD OF DRIPPING OFF THE END OF THE SPOUT, THE WATER WAS FLOWING BACK ALONG THE BOTTOM OF THE SPOUT TOWARD THE FIREWALL, THEN WICKING THROUGH THE BLACK FOAM BACK INTO THE PASSENGER COMPARTMENT, RESULTING IN A SOAKED PASSENGER SIDE FLOOR. FORD OFFERED TO REMOVE MY DASH TO FIND THE PROBLEM FOR A COST OF $800 IN LABOR ALONE. THIS SEEMS TO ME LIKE A DEFECT SINCE THERE ARE THOUSANDS ONLINE HAVING THE SAME ISSUE. I FELL THAT FORD NEED TO FIX THIS DEFECT FOR FREE.I DO HAVE A BUMPER TO BUMPER COVERAGE THAT DOES NOT COVER THIS CAN OF REPAIR. I AM UNABLE TO USE THE AC OR VENT WITHOUT HAVE WATER UNDER THE PASSENGER SIDE RUG WHICH GETS SO WET THAT IT TAKES WEEKS TO DRY OUT. I JUST DISCOVERED THAT MY WIFE'S 2005 TAURUS IS HAVING THE SAME PROBLEM AS MY 2002. REGARDS, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR