Fixing A Leaking Ac Drip Pan: A Step-By-Step Guide

If your AC is leaking, you may be tempted to replace the whole system. However, there are some DIY solutions that could save you thousands of dollars. The first thing to do is to identify the source of the leak. The most common reasons for a leaking AC are a defective drip pan, a damaged drip pan, an improperly installed drip pan, a frozen evaporator coil, or a clogged drain pipe. Once you've identified the source of the leak, you can try to fix it yourself or call a professional. Some possible solutions include using a product like PANSEAL Cartridge or JB Weld to seal the leak, or replacing the drip pan if it is damaged or corroded. If you're not confident in your ability to fix the leak yourself, it's best to call a professional to avoid further damage or voiding any warranties.

Seal the leak with a product like PANSEAL or JB Weld

If you're looking to fix a leaking AC drip pan, one option is to seal the leak with a product like PANSEAL or JB Weld. Both products offer strong adhesion and can be applied to a variety of surfaces, including metal, making them suitable for repairing drip pans. Here's a step-by-step guide on how to use these products effectively:

Using PANSEAL:

• Clean the surface: Start by removing any dirt, dust, oil, or other contaminants from the drip pan. Use a pressure washer, grinder, wire wheel, or sandblasting to ensure the surface is thoroughly cleaned.
• Prepare the surface: If you're working with a stainless steel pan, obtain a well-etched surface. For concrete surfaces, prime the pan with a suitable primer, such as DX-1100 Primer for Concrete, before applying PANSEAL.
• Mix the PANSEAL: Power mix part A resin separately, then add part B hardener and power mix again. Make sure to mix thoroughly until you achieve a uniform colour.
• Apply the PANSEAL: Once mixed, be ready to apply it immediately. Pour the PANSEAL directly into the drip pan or use a medium bristle brush, a short-nap synthetic roller, or a spray application for larger areas.
• Seal the leak: PANSEAL will self-level towards the slope of the leak. However, you can also brush it to move the product throughout the surface area. Coat the entire surface to prevent future corrosion.
• Clean up: In case of any spillage, absorb and dispose of the PANSEAL in accordance with local regulations. Use MEK or Acetone for cleanup.

Using JB Weld:

• Prepare the surface: Ensure the surface around the leak is clean and free of any dirt, grease, or debris. Lightly sand or scuff the area to create a better surface for the JB Weld to adhere to.
• Mix the JB Weld: Depending on the product you choose, you may need to mix the two-part epoxy together. Follow the instructions on the product packaging for the correct ratio and mixing procedure.
• Apply the JB Weld: Using a putty knife or similar tool, apply the JB Weld to the leak and surrounding area. Ensure you apply enough product to completely cover the leak and create a seal.
• Smooth and shape: Before the JB Weld sets, use a putty knife or your finger (with gloves on) to smooth out the surface and shape it as needed.
• Cure and sand: Allow the JB Weld to cure completely according to the product instructions. Once cured, you can sand the repaired area to create a smooth finish if needed.
• Clean up: JB Weld can be cleaned up with water before it cures. Follow the safety instructions on the product packaging for proper cleanup and disposal.

By following these steps and using either PANSEAL or JB Weld, you can effectively seal a leaking AC drip pan and prevent future corrosion. Always read and follow the specific instructions provided with your chosen product for the best results.

Replace the drip pan

If your AC drip pan is leaking, it may be time to replace it. Drip pans are meant to drain water away from your AC condenser with an easy-to-use hose. If your AC drip pan has rusted or corroded, there's a good chance that it no longer works.

Before replacing the drip pan, you should determine the source of the leak. The first step is to turn off the power to the AC unit. Then, remove the front panel and the drip pan. If the primary drip pan is leaking, you will need to work on it in place, using a wet vacuum to remove any water inside and a towel to dry the rest. If the secondary drip pan at the bottom of the machine is leaking, simply remove it and drain it thoroughly.

Once you have identified the source of the leak, you can replace the drip pan. If the drip pan is rusted or corroded, you will need to purchase a new one. Make sure to measure the size of your AC unit and the drip pan to ensure that you purchase the correct size. You may also want to refer to your AC unit's user manual for specific instructions on how to remove and replace the drip pan.

When you have the new drip pan, inspect the old pan thoroughly to find the source of the leak. Then, place water sealant over the problem area. It is best to add the sealant to both sides to allow the compound to adhere to itself and create a stronger bond. If the surface is corroded, use fine-grain sandpaper to clean and rough it up before adding the sealant. Once the sealant has cured (at least two hours), sand down any excess glue and replace the drip pan.

Finally, turn the power back on to the AC unit and run it to test your repair. If the drip pan still leaks, there may be another issue with the AC unit, such as a blocked drainpipe or a corruption in the drain line.

Unclog the drain line

A leaking AC drip pan can be caused by a clogged drain line. Here are some detailed steps to unclog the drain line:

Locate the Drain Line

The first step is to locate the end of the drain line, which is usually found outside your home near the condenser unit of the AC system. It is typically a PVC pipe coming out of the wall and draining into the ground. If you cannot find it outside, it may be located inside your home near a bathroom or another drainage point.

Check for Obstructions

Once you have located the drain line, check for any obvious obstructions at the end of the drain. You can remove any blockages with gloved hands or a pair of pliers if they are within reach.

Prepare the Wet/Dry Vacuum

Remove the paper or cloth filter from the wet/dry vacuum to prevent it from getting ruined by the water. Although some models can vacuum small amounts of water with the filter in, it is best to remove it to keep it clean and dry. Additionally, make sure you have access to the AC drain line by removing any caps or plugs from the end of the line.

Connect the Vacuum Hose

Place the tip of the vacuum hose at the end of the drain line, creating a tight seal by wrapping a cloth or duct tape around the connection. This step is crucial to ensure the vacuum can effectively suction the clog.

Turn on the Vacuum

Turn on the wet/dry vacuum to its highest suction power for 5-6 seconds. Check the waste compartment to see if you have successfully removed the clog. If not, repeat the process in short intervals until you have run the vacuum for a total of 1 minute. If the clog persists, you may need to call an HVAC company for further assistance.

Alternative Methods

If you do not have access to a wet/dry vacuum, there are other methods to unclog the drain line. One option is to use a plunger, which is a cost-effective and easily accessible tool. Another approach is to blow air through the line using an air compressor or bicycle pump, but be sure to cover the end of the pipe with a rag to prevent water from splashing back at you.

Preventative Maintenance

To prevent future clogs, it is recommended to clean your AC drain line with bleach or vinegar annually, especially before the summer season when AC usage is high. Pouring a cup of bleach or vinegar into the drain line will kill and prevent the buildup of mold, mildew, and other debris. Regular maintenance will help keep your AC system running efficiently and reduce the need for frequent repairs.

Check for a frozen evaporator coil

If you have a leaking AC drip pan, it is important to check for a frozen evaporator coil. This is because a frozen evaporator coil is a common cause of a leaking AC drip pan.

To check for a frozen evaporator coil, first turn off your air conditioner and inspect your unit for any signs of condensation or ice build-up. If you notice ice, do not chip away at it. Instead, wait for it to melt before attempting to restart your air conditioner. You can speed up the melting process by turning on only the fan setting on your thermostat, or by using a hairdryer.

If you have a window air conditioner unit, make sure it is tilted so the indoor portion is slightly higher than the outdoor half to ensure proper drainage.

If you have a frozen evaporator coil, it is likely due to insufficient airflow. This can be caused by clogged or dirty air filters, backed-up drain clogs, low fan speed, or a dirty evaporator coil. Check to see if more than a quarter of the registers in your home are closed, as this can also lead to frozen evaporator coils.

Low refrigerant levels can also cause frozen evaporator coils. If you suspect this is the issue, contact an HVAC professional to recharge the system and address any leaks.

Check for a broken condensate pump

If your AC unit is installed in the basement, the condensate pump should be pumping water outside. If the pump is broken, water cannot be pumped outside the home, and this can lead to water damage. Have this part repaired or replaced as soon as possible.

Condensate pumps are necessary when gravity cannot carry the water from the drain pan outside. If your AC unit is below ground in a basement or in an attic with an elongated condensate line, a centrifugal pump is needed to push the water along. Once the condensate from the evaporator coil reaches a certain level in the pump’s tank, it triggers the float switch, and the pump is activated.

Like any other AC system component, the pump can fail. If the tank or tubing for the condensate pump cracks because of long-term usage, the water will escape and drip or pool around your AC unit.

Frequently asked questions