My 07 XK has a water leak that is leaking on the passenger side footwell on the inside. Some people said it was the duckbill or some other minor fixing but I don’t believe that is the case. My mechanic finally got the whole ac box out. I am at the point to where if I need to tell him to order a whole new box from the jaguar dealership for $2500. Or see if he can repair it himself which isn’t a guaranteed fix. Does anybody have any experience with this situation? What could it be? Do I need to replace the whole box?

as you can see in the picture the guy I bought it from already tried to fix an auxiliary drain in there but that just didn’t work. When I make left turns I can hear water hitting my motor blower causing lots of noise.

 

I would be quite a surprise if it was not the duckbill as this part did not get corrected until many years later. Good news is you can get to it quite easily now. Also might as well replace the blower and resistor while you are in there for less than $100 and also if your dash hasn't already had the shrinking leather issue at the windscreen, it would be a good time to secure the edge with some glue and staples.

 

Unfortunately my mechanic didn’t find anything wrong with the duckbill.

 

Thanks for the other tips though. Anything else I should attack/check out while I got this whole front dash out?

 

Look for possible damage/cracks in the housing above the duckbill. Maybe pour some water through the air inlet and see if it leaks down through anything.

Check the air filter housing and inlet for damage also. Maybe rain water is getting in there from outside? Or are you positive is condensated water from the AC?

 

It is definitely condensed water. When it’s dry/no rain it is still leaking water. Mainly when I accelerate and make turns the water comes out/makes noise.

 

What I would do in your place is verify that there is no breakage in the plastic to prevent condensation water from the air conditioning from leaking out there.
The only water that can get out of there is the condensation of the air conditioning or the antifreeze water of the engine cooling since it passes to the radiator of the heating, but if you have not lowered the level of the engine coolant, you have the problem in a crack in the plastic shell or covered duckbill.

 

If you are convinced the it's condensate water, it's possible the inlet at the drain is clogged with fuzzy dust and other strangs things. Did your "guy" blow compressed air back through the drain line?
I've not, yet, removed my unit, therefore, I ask can the bottom half of the Evap case can be separated for cleaning that area?
Yeah, a perfect time to correct those other know inherent issues.

 

Even if the duck bill is fine, you should do some kind of upgrade to it to ensure it never is a problem.

 

WOW! I don't think your mechanic knows anything about Jaguars. This should be a super-simple fix. I circled the drain in the pic below. It goes through the firewall. If it's not clogged right there where I circled it, then there's a crack in the plastic somewhere. But even if there was a crack you should still have almost ZERO drippage onto your fan because the drain is at the low point. The drain would have to be clogged for enough water to build up and pour out onto your fan.

Bottom line, your drain is clogged. Period. End of story. If the drain wasn't clogged you might get a small amount of leakage through a crack in the plastic, but the majority of condensation would still drain out through the drain hole. The ONLY POSSIBLE WAY for condensation to fill up the condensate pan and pour onto the fan when you make left turns would be for the drain to be clogged.

 

Cut off the duckbill (don’t fix or replace), dry out the unit, replace the blower and resister, as said above, and reinstall. Problem solved. There’s no other mystery here, it’s a well documented issue that lots of us have faced.
And yeah, great time to take preventative action on your dash leather.