jdoc1949

This is weird, I have foam pieces coming out of left and right ducts on the dash board, the center dash ducts are clean.
Has anybody ever seen this?

Always wanted 1

It's is foam that disintegrates over time. My 2000 with 20k miles suffers from this as well. Someone else can chime in but I think it's from the door that selects hot or cold. You can close all but one vent, get a shop vac and turn the fan on high to get rid of it.

FRUNKenstein

Very normal. Lots of threads about that issue in here. Come to PCA breakfast at 7:15 am this Saturday at LePeep at 79th and Quivira and you'll meet lots of other 996 owners to share info with. Great group of folks. You don't need to be a PCA member to attend. www.kcrpca.org

808Bill

Not just a Porsche problem. My 04 RAM had the same issue.

Billup

I find it oddly satisfying to stick needle nose pliers in there and pull out a nice big chunk.



Or, I'll stuff a bunch of it back in the passenger side vent then turn the fans on max so my date needs to go inside so she can go inside and "freshen up"

Evilfrog

Anyone know what's actually losing foam? I'm assuming the inside of the ducts are lined with it. Or is it just a screen somewhere?

5CHN3LL

The foam is used to cover the diverter flaps. The flaps are perforated; the foam is supposed to make air go around the flaps instead of through them.

There's a DIY here from someone who replaced the foam with duct tape...

Here's Gator996's photo showing a foamless panel:

Device2

Bits of foam coming out of HVAC vents. BHMav8r thread in the 997 forum can elaborate more on the subject, the effects as well as the function of the foam and the flappers.

How to repair DIY write up and instructions: (in order to do the complete fix, the dash needs to come out).
https://www.dropbox.com/s/gja11v6yi6...ement.pdf?dl=0

The material is the foam lining from the two air diverter flappers inside the AC & Heater core air distribution assembly, as 5CHN3LL elaborated the foam does degrade and fall apart as these cars age. First picture is the location of the two flaps within the air-box. The second picture is that of the bad old disintegrated foam on the flapper, third picture is of a repair and what it is supposed to look like, TAP18230 foam insulation tape was used.

jdoc1949

Hello guys , thanks very much for all the good information, I understand the problem. I think I will try and do the fix as per one of the other post and cut the "****" from the top and remove flapper.
Thanks again
John

Vipertag313

What i call a "quirk" of the brand.. My 03 996 has the problem, my fathers 06 997 and '13 Boxster S have the foam in the vents.

Schnell Gelb

Before you start this awful job , I suggest you read up on the effect the deteriorating foam has on heating/cooling. In some climates, it makes no significant difference.