This discussion is another look at the infamous XK wet floor, condensate overflow, duck-bill issue.

The subject 2010 XK was produced 364 units before the VIN B34500 modified duck-bill. So, the insulated transmission tunnel concealed the old-style duck-bill. Repeated attempts to find the duct-bill without destruction of transmission tunnel insulation were unsuccessful.

Experience with building HVAC systems and related condensate problems suggests that accumulated dirt and mold may contribute to condensate back-up in our cars. Bore scope examination of the evaporator coil, looking for another way to clear the drain, did show dirt on the coil.

An effort to find an alternative solution to the blocked condensate drain included adding a cleaning solution in the AC condensate pan by way of the fan motor opening. WD-40 cleaning degreaser was selected because it is safe for the aluminum evaporator. A 54" long 3/8" ID plastic tube and funnel were used. The natural curvature of the tubing was used to roll the tube down into the evaporator pan. The same rig was later used to insert water for flushing and testing.

Twelve ounces of the cleaning solution was allowed to soak the evaporator pan and drain for a week while awaiting fan motor parts. Although the level of the cleaner went down, as observed with borescope, the drain did not clear.

Renewed efforts to find the duck-bill from the engine compartment were successful after removal of portions of transmission tunnel insulation. The insulation cover is tough, resistant to tearing.

So, consider a cut exactly above the seam on the transmission, six to seven inches deep and a parallel cut three to four inches toward the right (ROW passenger) side.

After removing the insulation, the duck-bill was found manually as described elsewhere on this forum.

The borescope was positioned to observe the duck-bill and a probe was used to manipulate the part.

With practice, the “lips” of the duck-bill were opened with the probe and “milked” of a slow moving “goop” by pushing and pulling the probe. When no further goop came out, water was added to the evaporator using the flush and test rig. Initially, the water dripped reasonably well. After half gallon or so of 8 to 12 oz flushes, the water rushed out of the duck-bill almost as fast as it went in.

I recommend the WD cleaner procedure as a preventative measure on our XK/XKR vehicles.

The probe used was fashioned after information provided in the many solutions offered by others, too numerous to mention. (Thanks KennyB - post #151 A/C water in Passenger foot well) Quarter inch round aluminum was chosen because it was on hand in my shop.

Thank you to all of the Jaguar Forums members who have contributed to this topic.

WD-40 cleaner was chosen because it is safe for the aluminum evaporator.

Fifty-four inches of 3/8 inch plastic tube was rolled into the evaporator pan through the fan motor opening. The funnel was perched above the door hinge, plan on blowing through the tube to clear the low portion of fluid.

A probe was fabricated from 1/4 inch aluminum round stock because it was on hand in my shop.

The 8 inch dimension allowed 2 inches of movement to reach the duck-bill located 6 inches behind the firewall.

Slow drip of water from the duck-bill on the initial water flush test.

Duck-bill full flow after about 1/2 gallon of water flush test. Flow rate out was almost as fast as flow rate in.