After camping trip from TX to OK and back, was cleaning out cab and noticed a LOT of water on underside of passenger floor mat. Further inspection revealed insulation beneath carpet was thoroughly soaked and suspected a clogged condensate drain.

Turned out it was clear and defect is metal sleeve clamped on condensate drain where it goes thru the firewall. Because there's a seam in the sleeve and no elbow in the drain, any slight incline will be sufficient for water to flow back along the seam and drain behind the carpet/insulation.

This fault extends to the Expedition, F-150,, F-Super Dutys, and Lincoln Navigator built after 8/31/2018 thru to the '20 model year.

The TSB notes that 'some' may exhibit a water leak. But looking at the installed metal sleeve, virtually ALL will leak if you use the AC for more than a grocery run.

After snapping the plastic sill plate and kick panel loose, I've puled the carpet back, stuffing towels between the floor pan and carpet/insulation with a fan blowing on them which should dry things out.. Fortunately, there was no mold but again, in most circumstances, there WILL be if left uncorrected. And Ford has been loath to replace moldy carpet stating it will be dried and sprayed with an antifungal unless the owner's raised hell with the owners.

The fix is to pull the metal sleeve off with pliers and install the prescribed Ford service part into the condensate drain which should solve the problem. It's also covered under warranty, I just don't want to leave my truck for two days while they rotate it into the service bay and I doubt they'll sufficiently dry the carpet. So much for 'that new car smell...'.

My bigger complaint is that I had the truck in just last week for the common 10-speed transmission 'clunk' when starting as well as problems with the Sync; also a NHTSA recall on the battery cables. While it was there, WHY didn't they simply fix the drain since it's only a .6 hour job? So if you've been running the AC, take a minute to reach up to the top of the passenger side carped and get your fingers behind the insulation pad. If it's just damp, get to your dealer; and even if it's dry, schedule a visit to have the elbow installed since it's only a matter of time before it becomes an 'Eeeewww' moment.