foam particles coming from all HVAC vents

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?

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

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-)

Be sure to replace only with N-rated foam.

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

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

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.

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 !

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.

It's happened to many brands...

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.

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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

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.

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Bingo. That is as far as I have gotten. D.

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.

My 99 C2 did this the day I bought it (used) in 2016. You can put the Blower on max speed and close all but one of the center vents. Wiggle the air vents up, down, side to side. Lots of foam comes up. Repeat for all vents. Do the top windshield vents and bottom floor vents. Then take your car to get it hand washed.

Another way to address it https://rennlist.com/forums/996-foru...outside-2.html

Just give it a few years and eventually most of the particles are done coming out.

I have the same problem on a 03 TT. I have dealt in foam for most of my career so I will offer some information that may clear up what I think is a misunderstanding. The foam on the blend doors is what is know as reticulated polyester foam and it does oxidize causing it to fall apart. By Porsche using this foam, it seems to me it is being used as a filter of sorts, allowing air passage because reticulated foam is used for filters. So, replacing it with a closed cell foam will defeat the openings in the blend panels and change the air mixture. I believe it would be better to replace it with some other filter medium which would allow airflow, but not oxidize as quickly. I am looking into thin electrostatic filter material of metal "foam" or some more durable plastic compound.

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Subscribing to this thread because of your post.

Mine does it too but Im not spending 4 hours taking the car apart to fix it. It will all blow off eventually or the engine will blow because I didn't address that issue. we shall see which happens first.

"Mine does it too but Im not spending 4 hours taking the car apart to fix it. It will all blow off eventually or the engine will blow because I didn't address that issue. we shall see which happens first." This!!! I thought I was lucky on my high mile '02 C2, but last year the occasional piece or two started accumulating much faster. I vacuum the vents out regularly, (although great tip about closing all but one at a time), and it's something I can live with.

Subscribed!

I've been collecting a bunch of the foam so one day I'll shove it all in the passenger vents, turn it up to max, and have a confetti party.

wow just wow.............air engineers and the theory of hot air .....graphed

This has happened to every German car I've owned after they pass a certain age. I am convinced its not the quality of the foam they use, rather its the adhesive used to attach the foam. After a few hot summers (heat/cold AC cycling) the adhesive breaks down and causes particles of foam to detach. Either that or the adhesive degrades the foam and it deteriorates. I think they all use the same Wurth adhesive and I'm pretty sure they also use it on the headliner on my 944's as that adhesive simply crumbles and brings the lining down with it. Also on the rear shelf of my AMG, which is always exposed to the sun, its detaching from the base and the adhesive underneath is dust. Just my theory.