Well maybe to get your hopes up....I havent had much trouble at all after all of those were replaced.

 

Alright, got some pictures tonight. At the bottom of the housing, there's about a 1/4 inch wide channel that runs the length of the housing and tapers off as it goes towards the driver side. This channel appears to be a hollow space that was poorly sealed by a rubber compound. I still don't understand why the water is exiting here instead of the drain hole. I hope I don't have to take the housing apart and reseal it. Any ideas on how to fix this?


Here are the pics:

Wide view from the passenger seat.
http://img39.imageshack.us/img39/334...onleak15ju.jpg


Close up view of the underside. Arrow shows the leak.
http://img247.imageshack.us/img247/9...onleak32jz.jpg

 

UPDATE

I removed the heater core today to get a closer look at the evaporator. The drip pan is intact and free from debris. It almost looks like the fan is blowing the water out of the pan and into the pass. compartment. Should there be some sort of seal or insulation underneath the evaporator to channel the air through it? The air seems to be blowing right underneath it.