2000 Jeep Cherokee Leak to Passenger Side Found

For the past few years my Jeep Cherokee had been apparently leaking to the passenger floorpan. I saw a puddle there the other day and decided to investigate to find that my carpet was covered in rust and starting to mold, so I removed that side's carpet. I searched online for potential leak points and found so many that I didn't really know where to look. As I ran the garden hose over the cowl, I noticed the leak coming from the seal to the blower motor compartment. Underneath the cowl of a 2000 XJ, is your fresh air intake that runs through the middle of the cowl drain gutter. It has a little lip to keep water from getting in, but a lot of water could easily go over. The water was getting in over the lip and running down the air intake and seeping through the firewall seals for the blower motor.
To fix this, I removed the cowl and cut back the tin metal about six inches away from the intake and bent it back to get my arm in there. I took household silicone caulking and caulked around the lip of the air intake to seal it off. I then bent back the metal and used silicone to seal the cut I made in the tin metal. The metal is there to simply keep water from going directly down into the air intake, so I didn't worry about cutting it or sealing it back up as the piece I bent up didn't go directly over the intake. I ended up removing all of the carpet under the seats and Herculining the floorpan a after I had cleaned off the rust in case of further leakage.
There are many potential leak points on the XJ models and this is merely one of them. I hope this video helps!

[@travisstone7720]

This video saved me my girlfriends jeep did the same thing and I did the test and it's leaking at the same spot yours was thank you for doing this video helped alot!

[@f.demascio1857]

Thanks for sharing. This has been an issue for so long in so many years & sub models. One would think Chrysler/Jeep would do something.

[@jackdooley8732]

ZKN ; your XJ is a beaut compared to mine. I'm gonna keep it till the wheels fall off. Nice work.

[@drecd5]

I also have the same exact leak on a 92 Chreokee. I debating cutting the cowl to seal the air vent under the cowl but not sure yet. I definitely can't reach the leak without removing the dash :(

[@riderjay253]

i have the same exact proublen on 2 jeep , did ya get fixed and how? i already tried silicone from inside and that wire bundle gets in the way, gotta fix in the cowl maybe

[@jasonlessard2373]

My 2000 did the same thing. The water was running down the firewall over the heater fan, leaking inside. The fix is to replace the heater box seal. Requires pulling the dash. (Didn't want to do that), I got some of the sticky seal tape. Looks like black taffy. I stuffed it down around the fan. I also cut a large funnel to make a hood to go over the fan motor like an umbrella. Then with the hose running on the windshield I watched the water flow, and made diversions out of rope seal, to direct the water away. It's a "back yard" way to do it, but without pulling the dash that about all you can do. ...do you like your fender flares? Did you have to cut the fenders?

[@Zaxx157]

Jason Lessard I love these flares. They look great and they provide an excellent table for tools while I’m in the engine haha. No fender trimming was required tho my 265s do rub when gnarly flexing.

[@andycheatle1732]

Zackaryan They are good lookin flares - I like my Cherokee 100% stock but if I was ever to modify mine your rig is a good role model! Looks sharp for sure

[@rosemaryruvalcaba9678]

Just did mine thanks for the video! My xj looks alot like yours I'm also eyeballing that smitty bumper how you like it?

[@drywallsculptingwithjason7137]

awesome dude i just pulled my carpet up found all the rust damage am waiting for new floor pan now and noticed after a hard rain last night that water was dripping from under passenger side in sure enough water on the floor dripping through rust wholes and i noticed mine is coming from exact same spot please update me on what you did to fix the issue

[@stuartbear922]

If I decide to remove the dash, is the seal still available?

[@cc5341]

Hey can you do another video about what you did to stop the leak. I have 99 that has the same problem. Just want to see the end result.

[@Zaxx157]

Lance Drudge I just posted a video today detailing the fix if you’d like to check it out.

[@JP105INYO]

Should be a recall or tsb lol. Damn Chrysler/Jeep

[@gort400]

Same problem. Where did you specifically silicone?

[@davidveach6319]

What fenders are those ..

[@davidveach6319]

Thank you I will look into that