NHTSA Complaint #10816236 — 2011 TOYOTA HIGHLANDER

HEATER/AC ASSEMBLY IS LEAKING ONTO A CONTROL MODULE UNDER THE DASH WHICH I BELIEVE THE THE AIRBAG MODULE AND SOAKING THE FRONT DRIVERS AND PASSENGERS CARPETS AND PADDING. CHECKED FOR BLOCKAGE IN DRAIN TUBE. NONE, USED COMPRESSED AIR TO BLOW OUT DRAIN TUBE JUST IN CASE. DID NOT SOLVE ISSUE. REMOVED PASSENGERS SIDE PANEL AND FOUND THAT THE FACTORY SEAM OF THE AC/HEATER ASSEMBLY WAS LEAKING WATER WHEN THE AC IS ON. (I HAVE VIDEO) THE DESIGN OF THE ASSEMBLY IS POOR IN THAT THE SEAM SPLITS THE ASSEMBLY LEFT AND RIGHT RATHER THAN TOP AND BOTTOM. REPAIR OF THE UNIT WOULD HAVE REQUIRED COMPLETE REMOVAL OF DASH, STEERING, ETC. TO SOLVE THIS, I PLACED 3M GLASS SETTING BUTYL TAPE OVER THE SEAM SUCH THAT THE SEAM IN THE UNIT WAS SEALED ABOVE THE CONDENSATION DRAIN. THIS RESOLVED THE ISSUE.