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Originally Posted by 00 Trans Ram
Been having this problem (New Orleans, LA). Took it to the dealership. Told them that they needed to log the problem and send to GM, but that they probably wouldn't find a "fix".
However, they did run some tests on the car. Found out that the actuator motor that turns the dampers for the defrost are working properly. They even reset them and sent voltage to them independently of the A/C controls. Still happened.
They tried a few other things, none of which worked. Their conclusion (like ours) is that the dampers simply aren't sealing the airway closed. Without removing lots of parts, there's no way to find out. But, they did send the problem up the chain, to be combined with all of yours.
On another note - how the heck do you put any kind of "coating" on the windshield to prevent this? The fog is on the outside, not the inside. You mean that you put something on the outside of the windshield? How does it stay on past that first rainstorm and 500+ windshield wiper passes?
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That was my thought as well, the condensate is on the outside not the inside of the windshield and is being caused by the blend door not closing fully for some reason allowing cold air to bleed up onto the windshield.