Leaking Evaporator Box Thread

Hello TW,

I have not seen too much information about this issue so I thought I would share my experience.

9/5/2020
My mom points out there is water at her feet after driving for 1.5 hours with the A/C running. It's a Sunday and the next day was Labor Day. No big deal, I'll schedule something.



Water was essentially dripping from the plastic evaporator box, onto the carpet, and then onto my floor mat.


Looked underneath the truck, the A/C was draining at a normal rate. Rules out a clogged drain.

The drive back yielded some more water but not as much as this.

9/11/2020
Was able to schedule an appointment in the afternoon. I show up, only to be told to go kick rocks because the issue wasn't happening at that very moment. Understandable, I did not want them to drive/idle my truck for over an hour just to see.

9/12/2020
The next day, I drove 2+ hours and lo and behold, my passenger was almost drowning in water! Took truck straight to dealer while I had the chance.

Initially, the lead tech wanted to tape some insulation around the evaporator box, then for me to keep driving around and monitor the area if it still leaks. I can't remember why exactly, so I won't type up false info.

Sure, why not? It's their problem since my 2019 is still under warranty at 21,000 miles.

Tech comes back to say they went ahead and just ordered a new evaporator box. He stuck a borescope up there and saw that it was leaking from a seam where the plastic box was molded together. Toyota Corporate just told him to stop messing with it and order a new part.

9/22/2020
The part was on backorder but I got scheduled to take the truck in. My rental was a Chevy Spark.

9/25/2020
Truck is ready for pickup. Got to glance at the paperwork, the job would be roughly $1200 if I was not under warranty.


All in all, Toyota took care of me in this case. I was told Corporate was a little sad because they actually wanted to see a Taco with this issue in the wild. Seems like this could lead to a recall in the future? Who knows.

I am also not sure if the new evaporator box was an updated design or not. The service manager did not really clarify that to me when asked.

Anyone have a similar experience?

 

Plugged up drain.

 

I take it u didn't read anything he typed?

 

Just because the drain has water coming out doesnt mean it isnt partially clogged.

 

True. In my case, the A/C drain was draining at a normal rate, even when it was leaking from the evaporator box. I did the A/C hose mod so I have some idea of what a normal drain was.

 

U mean you? It's a left handed thing you wouldnt understand.

 

So borescope and leaking seam had no bearing on your in depth diag of the clogged drain tube? Interesting

 

So I have been having this same issue on my 2019 Tacoma TRD Sport! I was thinking originally it was an issue with the windshield, since I had it replaced October 2021 at Satellite and they really messed it up. They didnt seal it at all on the driver side and water flodded my cab. So I was angry and told them it was leaking again!! Come to find out, they inspected it and found no issues with their installation, and I didnt believe them! I have a leak now on my passenger side, coming from up in the dash so I am thinking what else could it possibly be other than the windshield. We checked the cowl and the cabin filter.... dry and no issues. I pulled the AC drain tube and it isnt clogged.... no issues! Finally, I am searching on google and youtube and find these threads where people are talking about this known issue with the evaporation box condensation and leaking water on the floor. Someone posted he was going after the Lemon Law and Toyota is apparently aware of the issue, but will not recall. So I will make a complaint and contact the dealer, to make sure they are aware of the issues that are on going with these 3rd gen!! I have the picture here and it appears that is exactly where yours is coming from....

 

i might just seal mine up with some silicone from the outside. it's such a tiny area where it's leaking

 

Not for $1200 for me, more like $10. J-B WELD for sure.

 

i would try to seal it myself if i wasn't under warranty. might as well get it fixed right if someone else is paying for it

 

I had to do that on my Wife's old Durango when it was passed warranty. I just hotwelded with the plastic stick stuff from harbor freight never had another issue

 

so dumb they didn't seal it properly from the factory. seems like a common issue too.

 

I have a 2003 Lexus LX470 that this started happening at about 275k. I ordered a new gasket for the plate that goes on the front of the evaporator box. This immediately fixed it. I haven’t really looked at the tacoma one but it looks like it may be a different set up.

 

took mine into the dealership today and they confirmed the leak. they sealed it up with what looks like black rtv and it has been dry so far. crossing my fingers.

 

Any update on this? Just noticed a leak on my drive into work today from the exact same location as your photo. Would like to avoid the large bill from the dealer if this can be solved with a little RTV.

Thanks!

 

@MaverickT883 your issue?

 

the fix seemed to eliminate 95% of the leak. it will sweat a bit if it's extremely humid but that's about it.

update: nevermind, still leaking, just in a different area...

 

Just an update for anyone curious.

After the replacement, I have gone through two TX summers and many road trips with no issues. I am way out of warranty period at 81,000 miles.

Cheers.