Strong Mildew Smell After Rain. Two Dealers Can't Find Source/Leak

[Porpoise Hork]

I would try that but somehow I don't think the wife or insurance company would like me very much if I did.

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[JACKSMYDOG]

If it's in the headliner, you should be able to check pretty easy with removal one piece of trim and getting your nose in there. The gutter trim screws are 1 at each end, nothing near the middle. Maybe ~8 inches from either end.

 

[Porpoise Hork]

...And the plot sickens...

The dealership called me back letting me know that they had been on the phone with the engineer on the issue. He wanted to know if there was any standing water on the cowl. No standing water. Also wanted to know if there was any sign of water leaking into the AC system by inspecting it with a bore scope. No evidence of water leaking seen. The dealership reported the smell is present but faint when the AC is on fresh air but not when on recirculate, and that the interior of the truck does have a very strong mildew scent. The "engineer's" response to resolve the issue is to leave the AC system on recirculate and not switch it....

Yes really...

The service department has all but admitted that they are basically clueless at this point and are in a round about way stating that since they don't know how to resolve it and the "engineer's" solution did not resolve it then there's still nothing that can be done and I should just live with it.

I called the Ford rep handling the case and explained what I was told. I explained how absolutely ridiculous this "solution" is, and that just to satisfy my own curiosity I went to two different dealerships over the weekend and checked out several Rangers on the lots and none of them had this odor. I also expressed my concern that the longer this goes unresolved the greater the chance that the truck could develop a black mold issue creating a serious health risk. She reviewed the case and come to find out that it normally takes on average about 10 days for a field engineer to be assigned to the case. It's only been 6 days since it was escalated and that is including the long holiday weekend so it may take longer. This is something I completely understand and related that to her. She also stated that the dealership must have been in contact with the helpline support and that was where they got this information from, and would investigate it and notate it all in the case that their recommendation is not an acceptable resolution. She stated that the truck should remain at the same dealership even though I offered to get it and take it to another location. She's also supposed to call me back on Thursday to give me an update on the status and once the engineer has been assigned to it.

So I continue to wait since an actual field engineer has yet to actually be assigned much less given an opportunity to inspect the truck....

 

[Muscleford]

Sounds to me it may be time for a "Lemon Law" action and or a lawyer.

 

[Porpoise Hork]

Sounds to me it may be time for a "Lemon Law" action and or a lawyer.

That's crossed my mind, but would have to wait until the field engineer has been assigned and actually has looked at the truck and determined he/she is unable to locate or repair the leak issue.

 

[Porpoise Hork]

* Update *

Received a call from the service dpt. this morning at 7:30. They said that the field engineer had reviewed all the available information and directed them to replace the AC evaporator housing assembly and all related seals/gaskets. This will require the dashboard to be removed in order to get to it. They were also instructed to inspect the jute padding along the firewall for any evidence of water damage and replace it as needed. The dealership also said that field engineer has overnighted the required parts for the repair and the estimated time to completion is late tomorrow afternoon. Depending on parts delivery and their ability to pull it apart and back together correctly I should hopefully have the truck back tomorrow, but I'd rather pick it up Monday so they don't feel rushed and do it correctly. That'll also give it time to get rained on while they still have it to see if that fixed the leak or not.

 

[D Fresh]

Man I hope all that squares you away. This has been such a run around for you. Hope they finally got it.

 

[dapakattack]

Hope this takes care of it for you Bret.

 

[TuggerNutz]

 

[Porpoise Hork]

Mmmmm mildew pine. A combination to loose ones cookies over...

 

[Porpoise Hork]

Well it took nearly a week but the dealership was finally able to get the parts in. Apparently they drop shipped them directly from the manufacturer. For some unknown reason the manufacturers refuse to provide any sort of tracking information to the dealerships. It took multiple calls from the dealership and the Ford rep handling the case just to get them to confirm the shipment date. ?

But at least they have the parts in and are finally getting started on it, and are going to provide a loaner car to me now because they suspect the total repair time will be at least 4-5 days since they have to nearly strip the interior and replace the heater core and AC accumulator as part of replacing the housing assembly replacement.

 

[JeffWoodall]

Well it took nearly a week but the dealership was finally able to get the parts in. Apparently they drop shipped them directly from the manufacturer. For some unknown reason the manufacturers refuse to provide any sort of tracking information to the dealerships. It took multiple calls from the dealership and the Ford rep handling the case just to get them to confirm the shipment date. ?

But at least they have the parts in and are finally getting started on it, and are going to provide a loaner car to me now because they suspect the total repair time will be at least 4-5 days since they have to nearly strip the interior and replace the heater core and AC accumulator as part of replacing the housing assembly replacement.

I had this same nut roll with the Dealership on my F150 last year. To make a long story short, I had the same smell issues, etc. as you and could never find anything wet or damp. When the dealership "tested" where the leak was coming from, they used a water hose with a sprayer. Well, I found the leak myself, I used a pressure washer around all possible areas for a few minutes in different areas and the water was pouring in the back sliding glass window. It was obvious. It would just trickle with a heavy rain enough to cause the smell after it dried. They replaced the entire rear cab window, no more smell. Never had it again.

 

[Porpoise Hork]

I'm hoping that they will actually be able to find the water damaged area when they pull the interior out to replace the AC housing. Will have to wait and see once it's done I guess.

 

[Porpoise Hork]

Well. I finally got the truck back from the dealer. They replaced the AC accumulator housing and all the internals. The tech did not find any evidence of water damage in the jute liner along the firewall. They allegedly had it in the rain simulator tunnel for 2 hours this morning and parked it in the sun for another 3 hours and then checked it at noon and there was no mildew smell. I just went and got it and no hint of mildew smell. They are keeping the repair order open because they want me to test it out for a week or two and report back if the mildew smell returns. Also the side window weather stripping for all four windows is still on order and those are supposed to be in next week some time.

We're due another round of rain coming in tonight through tomorrow morning so that'll be a good test.

 

[Porpoise Hork]

And of course it didn't rain..

Stupid weather front came barreling through the state with a solid line of rain and at the last minute broke up going around my area of town like the parting of the Red Sea... Then kicked back up just south of my house to reform a solid line of rain...

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