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I can't help with the wall separation but I believe I can solve your wet furnace problem. Water intrusion is coming from the less than spectacular seal around the cover. Mine was so bad, there was corrosion on my circuit board and my dealer gave me a new board. To solve your problem, install thin weather stripping in the channel where the cover fits.Then re-install the cover and add two screws across the top of the cover to provide a better fit. I also put a "thin" bead of black RTV around the cover. It's a shame we have to apply modifications to something so simple as a cover!
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