I just called an A/C insulation company. They said I should have a 2 in. thick rap of insulation around that terminal box attached to the diffuser in the ceiling. Makes sense that a cold metal that's not insulated will weep condensation when exposed to warm humid air. I am 4 years out of warranty and the builder cut some corners at my expense.
Anyone who notices reddish/brown stains around their A/C vents, check to see if the terminal box is insulated.
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