How to fix this?

 

I've had this same leak. Water is traveling through the heater intake, through the blower motor, and on to the passenger foot well. It seems my problem is due to the air intake plenum (the plastic piece between hood and windshield) being cracked in several places. While it is a pricey piece, I just replaced it yesterday. While I had it off, I could see that water had been getting in through the heater intake. It appears that water could also be seeping in at the air intake around its edges. So I used silicone around that and on each screw holding it in. The deflector would be a nice addition to help this problem. Though with having everything apart, I'm not sure where the deflector would be placed. I plan to test the all my work against drips at the car wash in the next few days.

 

Is this under the black plastic cowl that the wipers stud comes thru? If so, mine is cracked in the center. What is sponge mentioned in the service bulletin?

 

Yes, it's that long plastic piece that the wipers come through and spans the width of the car. I think the sponge piece is gone from most trucks at this point. It acts as a filter. It would sit over the part of the piece that has all the little squares. Closest to the lip of the hood.

I bought that piece from Devon 4x4 in the UK. Even with shipping to the US it was still cheaper than all the parts places here.

 

This is what I used for a friends Disco that was missing the filter. I bought it at Home Depot for $12 and cut it into strips. It'll last you for years to come.

 

Rereading my post, it feels vague. I bough the entire plastic air plenum piece from Devon. It comes complete with the filter material in place.

Thank you JUKE179r, that may be useful for the future if the filter material needs replacing.

 

I used the cut your own from Home Depot before, As my scissor skillz must be lacking I found that it is not so easy to cut the material straight in as few sections as possible. soon had gaping holes between sections and rough edges.

I decided to just spend the $30 on the actual replacement foam pre cut to fit. It was easier for me and worth it to have it look less hacked.

 

Update:
The rains started early in Portland and I'm happy to report that replacing the air intake plenum and applying silicone around the heater air intake has stopped my leak! I hope that's helpful for anyone else with this leak.

 

Guys-
I am having the same issue with water in the passenger footwell. This weekend I replaced the center air intake hoping that the rain would not come through the interior fan but no such luck. I looked for the Rave bulletin to try to identify the factory fix (deflector strip) but was unsuccessful. How have others "sealed" the intake so that rain water doesn't run into the intake and onto the floor?
Thank you!

 

Upon further review...the drains at the end of the area behind the fresh air cowl were plugged with leaves and gunk. Not sure how to explain this but there was standing water (its raining here today) in the area near where the fresh air intake goes into the body. So when I accelerated, I suppose that the standing water rushed back into the air intake at the firewall. I kept hearing sloshing water and now I realize why. Anyway, I fished around and found the drain holes which promptly dumped the water behind the front tires as designed onto the pavement. SO, maybe (?) this will stop the leak into the foot well area. I do see how you might want to seal the firewall air intake fitting. If I can take good pictures and upload them I will.