aglaes

I've started to get foam particles from within the HVAC system coming out of all the vents. Have a 2004 996 Carrera. The foam seals, etc within the HVAC system have disintegrated and the pieces coming out, just crumble into dust in your hand.

What's the fix for this?

Bubrubb

Wear sunglasses and buy a Shop Vac.

I believe the entire dash needs to come out of the car to replace the divert-er flap that is covered with the foam that is disintegrating.

https://rennlist.com/forums/997-foru...vac-vebts.html

aglaes

Thanks for sharing the link. It's not actually my car, it belongs to a friend, but I'll be sure and tell him about the sunglasses and shop vac B-)

Cuda911

Be sure to replace only with N-rated foam.

Blue Chip

Small pliers and some time. Crank the blower all the way up and remove... piece by piece.

meirschwartz

Just in case someone feels like doing it right.
I have done it on my 01 Boxster, and the 996 should be similar process.
http://986forum.com/forums/diy-proje...am-flakes.html

mlee2122

crud... i just noticed this the other day. Had small pieces of foam in the vent, was wondering where it was coming from. Thought is was just a foam seal. Would have never figured it was coming from a door covered in foam. I was also hearing a little rattle as well coming from inside the dash. Looks like a real hassle to repair considering you have to take off the enitre dash. I guess i'll live with it for now. Maybe a good a winter project. I tried to look for new diverter flap or at least n-rated foam material. I checked Pelican, ebay, etc... and can't seem to find any. Did searches and can't seem to find source/supplier.

Schnell Gelb

This may work?
Foam sheet for HVAC
http://www.aeroflexusa.com/products/...arge-surfaces/
Whatever material is chosen - make sure it is the best .You don't want to do this job twice !

fpena944

This must be a Porsche thing. Had it happen with my old 944 years ago, have it happening now with my 996. Most of the time it's just little particles but sometimes a big chunk will fly out.

I just pick them up and move on.

808Bill

It's happened to many brands...

porschedog

I wasn't sure what was going on when the process began in my '03. Now it's down to a random, occasional bit of grey dust popping out.

IkoIko911

happened to all VW and Audi's too....

I just crank up the blower and use a shop vac every few weeks to clean them out

docmirror

There's a quick fix, that requires grinding off the top of a plastic coupling stopper on the outside of the HVAC unit to access the flapper. If you search for foam blower fix it'll pop up eventually.

Debo18D

Bingo. That is as far as I have gotten.


D.

Debo18D

But if I do decide to fix it, it will be like this most likely. This may be the method that docmirror was referring to.


https://www.scribd.com/document/212147792/986-Heater-Flap-Repair-Boxster-foam




d.