Since your passenger-side floor is getting soaked, the problem is almost certainly a clogged or disconnected drain hose. Water from the air conditioner's condensation collects in a pan and should drain through this hose to the outside of the vehicle.
Finding and Fixing the Problem:
1. Visual Inspection (Difficult): Try shining a flashlight up behind the glove box and along the underside of the dashboard on the passenger side. You might be able to spot the hose if it's disconnected or visibly clogged.
2. Remove the Glove Box (Easier): Removing the glove box will give you much better access to the area. There are usually screws or clips holding it in place. Consult a repair manual or online resources specific to the 1996 Windstar for precise instructions on glove box removal.
3. Locate the Drain Pan: Once you have better access, try to locate the condensation pan itself. It's usually a plastic tray. The drain hose should be connected to this pan.
4. Check for Clogs: If the hose is connected, carefully check for clogs. Use compressed air (low pressure) or a small wire to clear any debris.
5. Check for Disconnection: The most common problem is a disconnected hose. If it's disconnected, carefully reconnect it, making sure it's securely attached.
6. Check the Drain Hole (Outside): There might also be an exterior drain hole that could be clogged with debris. This is less likely to cause complete saturation, but worth checking.
7. Consider Professional Help: If you're uncomfortable disassembling parts of your dashboard, it's best to take your Windstar to a mechanic specializing in older vehicles. They'll have the experience and tools to diagnose and repair the problem efficiently.
Important Note: Before attempting any repairs, disconnect the negative battery cable to prevent accidental short circuits. Always refer to a repair manual for your specific vehicle model year for detailed instructions and diagrams. Repair manuals are available online and at auto parts stores.
