Is there a link to a DIY for a fix for the A/C Foam problem? I've seen several 996 ones, but would like to review a 997 version before starting this to see if there are any differences.

Thanks in advance.

 

This is the one I followed to do it for my 997.1 C4S Cab:

 

The main drawback with the method above is that it only allows access to one flap. I've tackled this repair on my 996 using a different method where you come in from behind the radio and cut the AC duct giving you access to both flaps (method shown in video below) but I never read of anyone on the 997 forum trying this.

I'm about to help a friend tackle this on his 997. Has anyone here accessed both flaps by cutting the duct behind the radio? The duct routing looks slightly different in the 997 parts catalog vs. the 996 parts catalog, so it may not be possible. We can always default back to the "remove heater core" method, but it would be nice to access both flaps if possible.

Thanks.

 

Not much help but I’ve got the hvac trim/vents off so if you need any pics let me know.

what’s up with the giant blob of duct seal in the video?

 

Not sure what blob of duct seal you're referring to. There are two vertical cuts that have to be sealed shut. Thanks for the offer RE: the pictures. I think what we really need to see is what is behind the PCM. The 996 has a vertical duct leading to the upper center vent that when cut provides pretty easy access to both flaps. The 997 does not seem to have that same vertical duct when I check the PET diagrams. We have to pull his PCM soon anyway because the screen went black and needs to be replaced, so we'll get back there soon enough. I'm just curious if any of the 997 guys have tried it. If it can be done we will for sure post a video documentation of the repair.

 

sburek's video contained the blob at around 14:10

 

Oh, that's to hold on the small "cap" that you cut off to slide the flap out of the box. You could also use a little epoxy or JB weld. You just need something to secure that piece back onto the top.

 

Were you able to determine if one can come in from the cabin and then behind the PCM to be able to access both flaps to perform the repair?

 

Is this strictly necessary? I've watched a few of these diy videos and it doesn't look like fun work. If I noticed foam coming from my vents, which I rarely run the heat so haven't noticed this yet, what's the harm in just letting it run out of foam?

 

There's no "harm" in doing nothing but you may not get maximum, or even adequate, performance of the temperature control in the cab. Or, some have the "weird" condensation on the windshield for which there's an aftermarket quasi-remedy.

 

Having gone thru the pain of fixing mine, I can’t disagree with your logic. For me, it’s when it started staining the carpet, my clothes or the clothes of my passenger that prompted me to call an end to it.

 

Has anyone completed this on a 997?

I’ve looked around and found quite a few 996 examples and it looks like going via the heater core will allow me to fix at least one bad flap, but I’m probably going to have to disassemble a good chunk of my dash this coming winter anyway, so if anyone has gone through the dash and repaired both flaps, any insight into going that direction would be appreciated.

 

I’ve done it on a 987. If we happen to share the same HVAC configuration you’ll find it’s not feasible to go in from the dash side as shown in the 986/996 videos. If you remove your radio stack you will know for sure. I followed some posts on this site and went in from the heater core and managed to repair 2 flaps. It was rough but doable.

 

I did the ‘through the heater core’ on my 2006 997 and was able to redo the one that you can fully remove via that approach, but haven’t tried to tackle the internal one that controls the movement of the air between defrost/dash/floor. That one’s on my winter project list since my car is a cab. It still blows my mind that Porsche put that crap in the HVAC on these cars.

 

The thought of cutting anything in my 997.2 is not something that I’m comfortable with. What I did was get some mosquito head mesh nets from Amazon. I then drove around with the air on full blast with a mesh net taped over each vent to collect the little bits. I did that a few times and I don’t have any foam blowing out anymore. For the condensation on the windshield issue, I got vent covers from Vision Vents. They look oem and are barely even noticeable.