The evaporator is leaking into the cabin WHILE the drain is clear and dripping out side the firewall like it's supposed to.
I've blow compressed air into the drain and used a wet vac to suck it out with no change. I tried duct seal to plug up all the obvious culprits including the missing firewall gasket but no luck. It seems to be coming from the tray ABOVE the drain between the firewall and the plastic cowling wicking down the rubber insulation. I don't see how the bottom tray comes off. Is there a seam up in there?

Clearly the PO has been here before so no telling what the old repair looks like.
What's involved with getting the drip tray out? Is this as difficult as it is on the 240?
Thanks

It sounds like the previous explorer did not seal things up properly.

The cover alone is not all that difficult to remove. This is an image of the cover in one of our 1994 940’s. The 8mm (5/16”) screws are hex head and a couple of them are a challenge.



These tools were most helpful in seeing and accessing the screws. One responded well to the low profile ¼ drive racket. The LED trouble light works well in the cramped space and won’t burn your face…..

tools

This is the product that I used to reseal the cover. The strips themselves are too large to use as is but they can be reduced in size by simply rolling them in your palm.

mastic

While you are in there see if the evaporator is sealed enough around it edges to prevent a lot of the forced air from the fan to bypass going through the evaporator coils. The replacement I installed was fairly generic and required some adhesive back foam strips to prevent air from going around the evaporator.

Good luck.

Randy

Excellent, thanks.
Charles