I'm wondering if it's just the expansion valve and its soaking the drain seal which is causing the inside to leak. What are your thoughts?

 

Does the a/c work?

 

Heater core?

 

I feel cold air but its also 40 deg F here. It seems the compressor is kicking on then off.
Here is a video if you expand it you will see the clutch engaging and stopping quickly..

https://streamable.com/qhfd6p

 

Doesn't matter what the ambient temp is, since air conditioning system runs whenever you turn on the defrost mode. It is designed to engage and act as a dehumidifier to remove the moisture from the air entering your vehicle to aid in removing moisture (fogging) from your windows. The compressor clutch engages verifies you have refrigerant in the system, and will short cycle since the low ambient temp would cause low pressure resulting in pressure switch sensor cutoff.

 

Are you saying there is not leak then?

 

I haven't said anything, I'm typing..
If it was an "ACTIVE A/C LEAK" it wouldn't take much time to leak out and cause your a/c compressor to become inoperative.
Have you had any repair performed requiring removal of the hvac case?
When was the last time you added refrigerant?
What are the current a/c pressures?
The expansion block is mounted with 2 bolts and 1 stud & nut, seals on both sides.
You can check/tighten the 13mm nut on the line to the expansion block, yet there are bolts under, that would require a/c evacuate/recharge system to check.
More information needed?

 

The only work that was done was about 3 to 5 years ago the expansion block was replaced. I'm hoping that is all that need to be done. I would hate to remove the entire dash.

 

Nothing needs to be done when the ac compressor is operating. In the meantime you can monitor a/c compressor operation, if it stops operating you have a legitimate concern. My a/c system is still all oem, operating properly, and I'm hoping the fridge is stocked with beer.

 

Does anyone have instructions on how to remove the hvac assembly so I can replace the evaporator. Seems to be leaking from the evaporator.