longdriver625

2000 Porsche 911/996 coupe

How to repair the heater flap seal now that foam is blowing out the vents without tearing the dash out. Thanks

DBJoe996

Stand by with a shop vac, turn on fan to high, suck up all the foam that blows out. Use tweezers to pull it out of the vents. Then....after a while...it stops. Mine blew out years ago and after the initial blow out, I've never noticed any difference in how the HVAC system works. You cannot repair the flap without pulling the whole unit out, that requires a complete dash removal. Somebody did a exploratory project years ago by removing the heater core and going in from the top by cutting away at the plastic pivot points and then repairing. Better to just let it finish blowing out the vents and moving on.

RT_955TT_KY

I went in from behind the radio and cut the center vent supply vertically on both sides. This allows enough room to get a hand down into the flap area. I used Gorilla tape to replace the foams function and some recommended foam tape for the edges of the flaps. A modified shop vac hose works great to get down inside and suck out as much old foam as possible. The plastic vent supply sealed back up fine with some silicone and Gorilla tape. Its been blowing hot, and foam free for a couple of months now. There are several good write ups I found by googling.

fpb111

There are a number of repair methods. See this thread

professorman

Based on these treads, I envision another year blowing that crap out for me.

bustersfarm1

Your method seems more logical that others -- can you perhaps give a little more detail on what you did? Any pics of what you did as well? Thanks