So this is totally out of the blue, but I got my 'Balt fixed... Finally. It took 3 trips to the dealer, but I ended up with essentially a whole new AC system. The first time they took the blower and everything under the dash apart and re-sealed it. It was fine for about a day, then it started to spray water out from under the dash AND fog was rolling out of my vents. People must have thought I was hotboxing my car while on the highway.
I took it back and they re-resealed everything and replaced the drain line thinking it might be plugged. They said they ran the car for a half hour and nothing happened. I get it back, drive it for an hour, and holy crap, it was like the dam burst. I had niagra falls under my dash. There was so much water it wasnt just coming out on the passenger side, it was backing up and spraying out on my feet too.
So back to the dealer it went, and they ended up replacing the whole AC system. New compressor, condenser, evaporator, and blower. Apparently there was something defective in the system and it was basically condensing too much and the evaporator wasnt working properly, so all the water had nowhere to go but out the emergency drain hole in the blower casing. At least its fixed and the car is running great now.
09 Cobalt LS 2.2L 5spd Silver Ice Metallic