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Air Filter Nightmare

651K views 2K replies 242 participants last post by  klp 
#1 ·
Just returned from servicing air filter at Ford Dealer on 3.7L Transit Van, and was informed that the air filter was saturated with water. Seems that every time it rains or snows, water will be diverted directly to the air filter box. Ford is aware of the issue, and has not offered a solution.

I suggest that all owners call Ford at 1-800-392-FORD with their concerns
 
#2 ·
#3 ·
Appears there are multiple points of entry. 1. the gap between windshield and hood near antenna, 2. joint in wiper tray near drainage hole not totally sealed, 3. gasket between hood and wiper tray not water tight.

There is a drainage/diverter tray beneath the left side (drivers) side drain hole, but none on the right (over the air filter), a major omission in my humble opinion, and not so difficult to remedy by Ford it would seem. At the risk of being redundant, Ford is aware of the issue, with no remedy thus far.

Again, calls to Ford ASAP would be indicated (squeaky wheel).
 
#4 ·
Update- It's raining here in beautiful Michigan, and the windshield wiper cowl is leaking like a sieve on the passenger side, right over, and on the air filter housing. The joint next to the drain plug (which is draining anemically) is poorly sealed and the main culprit. Plenty of water ingress directly off the windshield as well.

The drivers side diverter tray is working like a charm. The Ford mechanic rigged up a temporary 'diverter' to shunt most of the water away from the filter, until Ford 'engineers remedy the issue.
 
#7 ·
The saga continues- Just contacted by Fords regional rep., who shall remain nameless, saying she was sorry about my trouble with the Transit CONNECT!??!!, assuring me the 'engineers' are hot on the trail with a remedy in the offing.

I cleared the small tube leading from the minuscule drain hole, prone to icing and debris in the best of scenerios, waiting for dry weather to seal the joint adjacent. Again, the diverting apparatus seems like the only feasible solution, with multiple avenues for water ingress to engine department.

Sorry to be a negative Nellie (an indication of my age), being generally satisfied by the Transit, but this glaring oversight is troubling.
 
#12 ·
The saga continues- Just contacted by Fords regional rep., who shall remain nameless, saying she was sorry about my trouble with the Transit CONNECT!??!!, assuring me the 'engineers' are hot on the trail with a remedy in the offing.
Ford really needs to change the name of the smaller vehicle. Ford Buckboard or something.
 
#8 ·
Any chance of a photo showing the major entry points, maybe by using some yellow safety tape etc. to represent the path water can take? A shot from above the hood and wiper cowl/shroud to set the scene would be great. My Wagon is due soon, and I want to be able to inspect it thoroughly before I accept delivery.

Thanks
 
#10 ·
PeterR- not versed in the intricacies of photo sharing, but you'll plainly see the petite drain hole, the tube leading from it under the hood, and the unsealed joint adjacent. Also the gap between the windshield and cowl, and the lack of DIVERTER enjoyed by the drivers side.

On a not so humorous side note, my wife when notified of the problem, suggested we move to Arizona to remedy the problem. Also, a 30 gallon garbage bag over the air filter housing when it rains is prescribed. Sad but true.
 
#11 · (Edited)
Thanks bif, when my Wagon gets here I will check it out with the dealer. And thanks for taking the lead on this major design defect.

Anyone else up for taking some photos?

Another water intrusion problem area someone mentioned is the fasteners holding the lower side panels onto the Transit's sides. Any water intrusion noticed from these (perhaps on the interior where the side walls meet the floor)? Anyone with a passenger Wagon notice the carpeting being wet in this area?

Apparently Sprinters also had this problem, and you would think that Ford would have ensured that the new Transits did not repeat the Sprinter's mistake.

Edit -- 6:23 PM EDT -- here are some posts about leaks at the marker lights above the headliner, sidewall decorative panel fasteners, and other areas:

http://www.fordtransitusaforum.com/83393-post20.html

http://www.fordtransitusaforum.com/83009-post6.html

http://www.fordtransitusaforum.com/83265-post14.html

Edit -- 6:37 PM EDT -- window or weatherstripping leaks:

http://www.fordtransitusaforum.com/98465-post7.html

http://www.fordtransitusaforum.com/...ssion/7953-water-leak-top-left-rear-door.html
 
#13 ·
I keep mine in a garage so it stays dry, but I can see where some water has dripped onto the air filter housing.

What I don't understand is why in the world they designed it with the lid fitting inside the bottom instead of overlap the bottom to prevent this. Water has no where to go except in the filter box this way. Engineering 101 ??
 
#15 · (Edited)
Thanks for the specific problem ID!

Edit -- 8:55 PM EDT -- Actually the illustration from the owner's manual link I posted earlier shows what star gazer has said, although the illustration was not clear enough on its own to merit this conclusion IMO.

At the top right of p. 224, under point 3., is illustration E174669:

http://www.manualslib.com/manual/745073/Ford-Transit-2015.html?page=227#manual

[The illustration for the 3.5EB engine on the previous page is the same.]
 
#1,586 ·
The mechanic that did the repairs on my van last year suggested I go over to the local ford dealership and talk to the service counter about a recall/solution. In hindsight, I have just realized he seemed to be aware of the problem and likely had previous experience with the same issue.

The Ford Service Department denied that there had been a recall pertaining to the issue or a known history of the problem? However he did come out and look at the van and did do the same water test you described. He pushed and pulled on the plastic trough type thing above the air intake. He said that there must have been debris, leaves or other causing the trough to overflow.

I am a bit OCD and that is one of the things that I check and clean frequently, particularly in the spring and fall. I habitually clean out that area and have with every vehicle I've owned for decades. I am totally confident debris did not cause water to flow into the air intake.

I am thinking of getting a shower cap type of thing to cover the air intake at night or during any kind of precipitation when the van is parked?

Not much of a solution but it is all I've got at the moment!
 
#24 ·
Thanks for the heads up Bif, I checked mine and is wet as well , I called Ford and they have no open reports on this issue, She told me to drop off my van at the dealer and have their mechanic inspect it and send the report to Ford mine is due for a oil change soon so I will have them take a look at it.
 
#25 · (Edited)
This is really disappointing...

I realize this is not the same thing (different vehicle, sales volumes, etc), but every Corvette coming off the assembly line in Kentucky spends a couple minutes in a water intrusion test chamber where massive amounts of water are sprayed on the vehicle, to discover leaks.

Seems Ford should at least be sampling every n (n= 100?) vehicles using something similar.
 
#31 · (Edited)
Doubt if a seal or gasket can be a good permanent fix for the backwards overlap of the air filter housing's top piece fitting INSIDE the raised lip of the air cleaner housing's BOTTOM base, as you identified (and confirmed by the illustrations in the owners manual). Seems like the entire housing must be redesigned for a proper weather-tight overlap. Can this be done and still fit in the space allowed for the entire assembly?

Bet the 2016 model year version looks different altogether . . .

With my Wagon coming in soon, is this a deal breaker? TBD.
 
#32 · (Edited)
It's been hectic here trying to pack and move, so I haven't studied this entire thread yet. Last night while it was raining, I lay awake and cringed at what I would find today when I checked my long tall ext T350.



When I went out this morning and inspected under the hood, there was a drop of water hanging underneath the small water catching basin mentioned earlier in this thread. That drop of water was at the location of the small reusable fastener that holds the supply line from the windshield washing fluid line that takes washer fluid to the two outlets below the windshield. (There was a bit of dirt in the basin, but the drain tube was not obstructed). Apparently, Ford engineers decided to put the fastener in the BOTTOM of the catch basin that was supposed to divert water from the area, allowing the water to leak through the fastener hole directly onto the top of the very poorly designed lid to the air cleaner, which also can allow water into the air cleaner box.



It was also obvious that water with some dirt in it had dried around the poorly designed air cleaner lid. I haven't disassembled it yet to see if my filter is wet. But at least I can try and make corrections to the leaking basin where the small reusable fastener appears to be leaking water onto the top of the filter cover.



I hope this helps.
 
#33 ·
Update..

After overcoming my worst fears, I went out and took the lid off of the air filter box. DANGIT!!!!

The filter was still damp, and water was still inside the air box. There was NO gasket whatsoever to seal the air box where the poorly designed air box lid and box meet.
 
#34 ·
When my salesman gets back from vacation on Wednesday, and earlier if my Wagon is already at the dealer, I plan to go in to check this out, and see what they have to say about it. The head of the service dept. is a pro, so I am especially curious to see what he has to say.

Can you seal up joints etc. in the wiper cowling above, to prevent drips, and let the drain hole there do its job? Or does everything have to be re-designed, including the top AND bottom of the air cleaner housing?
 
#35 · (Edited)
They could/should probably redesign the top, to shed water OVER the outer perimeter of the lower part of the air box. And that would solve a lot. But even with this sh]tty design, they should have AT LEAST put a water tight gasket in the where the top and bottom of the air box join together to seal it up.

As far as he catch basin, it could be sealed up better. The catch basin is actually TWO pieces. The outer 2-3 inches of it, has a very poorly designed seam that I think is the source of the leak, probably NOT the screw that I mentioned in the above post. At any rate, I'm going to take the basin apart, clean the two pieces thoroughly, and put then back together with some silicon sealant, and put a rubber washer underneath the small screw the pierces the bottom of the basin, just to attach the windshield washer fluid hose that passes underneath the catch basin.

This still doesn't fix the lack of ANY gasket material between the two halves of the air filter box housing. I wonder how much silicates have been sucked through my EB. I'm headed to the hardware store to pick up some thin foam tape, silicon sealant, and the drug store for some rubbing alcohol to clean things up before I get started.

Someone's head should roll at Ford. This is so stupid.
 
#36 · (Edited)
It's truly a poorly design air filter box by Ford, after doing some googleing, apparently the folks in Europe are having the same problem with their Transits:

http://fordtransit.org/forum/viewtopic.php?f=5&t=80674.

After checking mine out and as Bif mentioned , there's a small tray on the driver side under the drain hose from the windshield tray if you will,diverting any water to the side. but no tray on the passenger side under the hose drain.
There's some electric wiring plugs on the driver's side so I guess they needed to protect them from getting wet, and they thought that the filter box its water proof so lets save some money there by not putting a water diverting tray there .
 
#39 ·
Husband went to dealer today. There is a TSB that has actually been issued. Have some issues to get resolved from the hail storm and slider that rattles when you drive down the rode.
 
#40 · (Edited)
BUT, BUT, BUT, *only* Sprinter people have problems with their vehicles....

*rolleyes*


I hope to helll they find a fix for this before I pick up my van next month. The last thing I need is to lose sleep everytime it rains or I take my truck through a carwash and wonder if my air filter turned into a wet sponge....



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