Does anyone have any pics of what this looks like? Is it worth trying to fiddle with it to get it moving or should I just order the part?

 

Pictures here.
See the Electric flap servos chapter.
Cheers,
Tore

 

Thanks Tore. I'll take a peek at them this weekend. Pretty sure this is my issue. Everything was fine then all of sudden, warm air coming from Drivers side vent and partial warm air from center vents, cool air from passenger vent.

 

Well, I pulled the kick panel, and pulled the mixer on the drivers side that was blowing hot with the A/C on. Everything works fine....flap opens and closes with the temp selector. Put it all back together and it's working fine. Must have just been stuck. Should I lubricate?

 

I had the same problem, took the servo motor apart and found some dirty contact points on the large center gear on the main axle in the box (the center piece in the attached picture). I scrubbed the contact points with a file, reassembled, and it works as it should. The whole process took a leatherman and a beer and saved me $280 on a new servo.

 

I removed the right flap servo on my 2004 Cayenne. It was stuck. I popped the top off with two little screwdrivers and then used a tiny 12v battery and telephone wire (thin and prone to heating up) to introduce current to the two leads connected to the motor itself. That worked. Turn the leads over to reverse. Add grease where appropriate. Cycle to work grease in until satisfied.

When it came time to put the next servo into "install" position I simply removed the cover, adjusted the position of the arm with the wire leads, and popped the cover back into place. No need to bother with the pinout and risks of a short if you go straight to the motor with the 12V.

 

I replaced the mixing servo in the footwell with a new unit, in the process of which the flap closes (manually) and was disappointing to see that it would still not work. I assume trouble in the CCU not „asking“ the servo to function? Any ideas on how I can test and more importantly repair this?

Passenger side is working fine.

 

It may well be that the failing servo has killed the CCU servo output.
However, did you reset the CCU after changing the servo? The CCU will not try to move a servo if it has been detected as faulty, but will try to move the servo again if reset. This means that the ignition must have been off for over 20 minutes, or you can briefly disconnect the battery.
Cheers,
Tore

 

I had not done that. Turns out, it works great now, thank you!