foam being blown out of the vents

Over the past few weeks, I have noticed pieces of foam being blown out of the air vents. The A/C appears to be operating normally (I have not noticed any issues with the A/C, in fact, it has been operating as it has been the past 9 years). Is this a common issue?

Same thing is happening to my '06 right now. Fortunately, it is in large pieces, which get trapped by the grates. I can reach in with tweezers/forceps/needle nosed pliers and pull them through. I have heard that it is a common issue.

this may help.... http://www.planet-9.com/987-cayman-...blems-and-complaints/109064-careful-whats-coming-out-your-c.html?highlight=foam

very common issue, been having this problem for 2 years now, so yours just started. i think mine is almost gone

Definitely happens with the older 986 gen cars. The cause is the hot/cold air mixer door under the front cowl. Foam covering gets brittle and deteriorates over time. Likely the same in 987 gen. Not sure about 981 . Interior vent debris - Page 2 - 986 Forum - for Porsche Boxster Owners and Others

Hey @eyeofthetiger Is it necessary to replace that foam (Sounds like a massive and expensive job), or does it not really serve much of a purpose. Started happening with mine, as the 987.2 starts hitting a decade old! Ooops.. a decade young!

An annual ritual of Spring - cleaning that black foam sludge off everything every day. After doing this for years, it seems to have finally abated. I'm not noticing any side-effects so I'm definitely not going to reload it with another batch.

Until I send it in to my local independent workshop, I think I shall refrain from wearing white shirts - That black foam is not just a foam, its kind of sludgy and can even stain! Lucky we have to wear face masks these days, otherwise I am kind of worried about the foam ending up in my lungs! Have to say I have not noticed that it makes the AC any less cold or effective, perhaps it affects heating more … And I hear it may eventually cause the windscreen to fog up?

hey there KL Cayman ... well strictly speaking its not a must - but just plain annoying... and yes it stains white clothes and the seats too (mine is a sand beige interior). You'll find similar foam in the headliner (dont go there...) RS Schwerer - i thought that too initially...and just when you think its over.... out comes more! just felt like it was never-ending. it took a hot day with AC running and chunk of foam flew out & up my nostrils to finally give in. the air direction can be affected as the foam degrades and sometimes cold air goes towards the windscreen (because the foam for the upper flow has degraded) and the result is a slightly fogged up lower windscreen. not a show stopper. Of course you can replace it with a different type of foam which hopefully lasts longer.

Hows it going, @eyeofthetiger Thanks for the reply! I agree, so far it is annoying, and after my clean-up a month ago, no other foam pieces has come out. I think I will wait until there's another "batch" of foam being ejected by the air-con vents before I send it to my local independent to rip apart my dashboard and do the repairs and foam sheet replacements. Thank goodness by 987.2 headliner had been replaced with a non foam material (In fact like a mesh, quite sporty!) by the seller who sold me my baby last year. Yes, my mechanic did warn that if more foam is rejected, it could result in a windscreen fogging experience, but I haven't yet seen that - So will wait till it happens before triggering another USD 250 workshop spending! Cheers...

Its the cover of the directional vents so you will notice as the black stuff disappears the ability to direct air to face or floor becomes impossible, it just comes out of both. If you can live with that, fine. If not there are videos on YouTube (of course!) on how you can remove your NAV, cut a little plastic and put some tape on the vents. Its a little brutal but seems a way to fix the problem. I am not saying I approve of the method but it gets the job done. (I haven't done mine yet but the black stuff has just ceased to flow on my 2006 Boxster S so considering it.

Thanks for the tips - For now, despite the 35 C day-time temperature here in Kuala Lumpur, Malaysia, I still haven't had to suffer from the inability of directing air to face (v floor). Perhaps if it gets worse, or more yucky black foam flies out, then I will send it to my local mechanic. Due for the next annual service in Sep-Oct anyway. New problem this morning - Leaking coolant spotted below the car (Faint-pink liquid), and I had to top-up 2L (or 0.5 US gallons) of water, otherwise the alarm for "Check coolant level" came on during each morning's cold-start. Time to send to my local workshop... I guess this is part and parcel of driving a 10 year old car, even if its a reliable 987.2 !