If the drain pan has a hole or crack in it, A sheet metal shop should be able to make a new one. I often have replacement pans made of stainless steel at a local shop.

 

You can cap the drain and poor water into the pan to test for a hole.

Did you shop vac the drain?
It will be easier if you cut the drain pipe and put the shop vac on the cut pipe.

Panseal is an option to consider if you have a small hole or crack in a pan.

 

 

If you really need to remove the evaporator coil, I would strongly recommend that you get an A/C tech with the proper equipment to come in and capture your refrigerant. Your A/C is old enough that it almost certainly uses R22 refrigerant, which is no longer being made. While R22 is still available (old stockpiles), it is quite expensive. There are 2 reasons for capturing the R22. First, the savings in purchasing new R22 will likely pay for the cost of the technician. Secondly, and more important, knowingly releasing R22 into the atmosphere is illegal and contributes to global warming.

 

 

I have a real conundrum. My AC duct is leaking into a room two rooms from the AC unit (unit is in a closet in the living room. It leaks constantly and evenly (so we thought it might be condensation) but when it rains the leak gets WAY worse. Is it condensation or rain or both?? Anyone have a way to troubleshoot? I have searched roof above for leaks and laid down some sealant already.

 

I would suspect it to be condensation. When it rains the humidity is higher & there's more moisture in the air to condense.

 

After 22 years, a new system should be considered.

 

Need a lot more info.
How is this system ducted.
Perhaps a picture of it would help. I have never heard of an A coil and blower in a living room closet!!!
Are you sure that this leak is due to the AC? Seems strange that it would leak two rooms away.
You say it leaks constantly so does it leak when the AC is not running?
Is it possible that you have a a leaking drip pan like the original poster?
How does the drip pan drain?
Etc, etc, etc.
This may be better fixed by getting a pro in as I think there are too many unknowns unless a person can see the actual set up.

 

This is an old post , but I ended up replacing my whole system, along with a new furnace and AC condenser.
The old metal drain pan was a mess, there was more then just one or two holes , it needed to be replaced so being so old , we decided just to put in a new heating and cooling system .