Water Leaking Underneath Furnace Cabinet

[afonje]

Hello Experts! I have a water leak issue with Model #: EDD2X36FA2 indoor unit. Manufactured by International Comfort Products. Here are the details from the label:

• Refrigerant: R-22
• Design Pressure: 300 PSI
• Factory Installed Metering Device: TXV (Thermal Expansion Valve)
• Date of Manufacture: April 2008

The issue began with a puddle of water underneath the furnace cabinet, at which point I got a shop vac and tried sucking gunk from the outside. I cleaned the water on the floor and the issue didn't come back for about a month. After a month, I saw another puddle of water on the floor and I decided to cut the 3/4" condensate pipe at the coil end and installed a new pipe to temporary drain into a bucket. That appeared to have resolved the problem, though I did had to use a rag to wipe off the floor on occasion, which I assumed was the remaining water that had become trapped beneath the furnace cabinet and could not dry entirely. I was OK with that idea until lately, when I noticed water drops trickling down the side from between the furnace cabinet and the air handling cabinet. This is on the side, not in front, of the stacked furnace and air handling units. I've also checked the evaporator coils and they're not frozen. Photo of the side of the furnace/air handler is below. Please give me some advise or suggestions on the issue at hand. I've also made some measurements with the system running, image is below.

Here's a summary:

1. Opened the cabinet with the evaporator coil and cleaned the pan with a rag. The coils weren't frozen.
2. Flushed the condensate drain with vinegar and warm water.
3. Installed a new p-trap.
4. Saw that the water drained fine out the other end (from the outside).
5. Discovered that water is building up in the seam on the left side between the furnace cabinet and the air handler cabinet. It seems like the blower motor is pushing it out, but I may be wrong. This water then finds its way to floor, and it's a never ending cycle of cleaning the puddle of water from the floor. I also used an air gun to push the water underneath the furnace cabinet so that I could catch it with a rag.

I'm not sure what could be the cause of this water build up along the seam on the side of the unit. I figure if the pan was damaged or cracked I would see the water drip on the inside, but I don't see that.
Any other ideas?

 

[Fitter30]

A coil surface is probably dirty and condensate instead of running down into the pan is falling off the coil. Take a look at the blower wheel look at the blades there probably dirty there cupped. If there dirty the coil is. Coil have no idea if it can be pulled out of the cabinet to inspect. Mix up some water and dish soap in a spray bottle spray it on the surface of the coil or evaporator coil cleaner. See if that doesn't take care of it.