8 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHHVAC on the table - total FIX!
Leading reported evidence
Repair (not 996)
Suggestion or failed attempt
No successful repair reported for this finding.
0
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0
Unsuccessful attempts
1
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Leading evidence: 'Repair (not 996)' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Repair (not 996)' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Suggestion
Hats off to you and others who've gone all in to repair the HVAC foam issue.
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Suggestion · Original poster
I've seen many repairs that only involved the repair of one flap.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Suggestion · Original poster
Hi, I decided to do a comprehensive HVAC repair on my 2003 996.2..
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
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Suggestion
Total pain in the *** but it felt amazing to replace ALL of the rotting foam in the dash.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
8 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 0 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261026T191851Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Hi, I decided to do a comprehensive HVAC repair on my 2003 996.2..
In this thread in the next posts I will inform about my repair.
I've seen many repairs that only involved the repair of one flap.
Some of the repairs I watched on YouTube involved pretty brutal cutting of vents. None of the methods satisfied me.
I found some videos on Youtube on how to remove the dashboard that helped me. On Youtube I did not find info on how to remove the HVAC after removing the dashboard. I also did not find a video or photos of how to dismantle the HVAC from the Porsche 996.
In this thread I will inform about my fix - all door blends..
To remove the HVAC I did:
From the outside:
- removing the battery
-removal of the skirting board
-removing the wipers once with the motor
-removing the cabin filter with the housing
- draining the gas from the air conditioning
-removing the heater
From the inside:
- removing the seats
-removing the center tunnel
- Removal of HVAC controls, radios
-removing the instrument cluster, vents, airbags
- removing the steering wheel
-Remove the turn signals and wipers
-removing the dashboard
-remove the A-pillar covers (to remove the dashboard)
The topic will be updated
The help I used:
Door blend repairing (not 996):
You Tube
Wiper windshield cowl:
You Tube
Dashboard removing:
You Tube
You Tube
You Tube
https://rennlist.com/forums/996-foru...l#post18737088
All translated by google. If something is incomprehensible - ask, I will correct it.
My pics:
Amazing, I'm about to do this in a few weeks too. I'm planning on using this foam from mcmaster.
https://www.mcmaster.com/8614K82/
,
https://www.mcmaster.com/8614K81/
The key here is using a very soft foam so the blend doors can seal properly without overtorquring the drive motors.
In case you need a new gasket between the cowl panel and air intake. The airbox is nearly exactly the same as used in Mk4 VW Jetta/Golf and first gen Audi TTs.
https://www.audiusaoemparts.com/oem-...sket-1h0819165
Well I did it. Total pain in the *** but it felt amazing to replace ALL of the rotting foam in the dash. Including the duct seals.
I made templates of the foam for the doors, I�ll get these in CAD and share them soon.
-Heat/AC blend door - 1/8� thick foam
-Vent outlet door - 1/8� thick foam
-Recirc/Fresh air door - 1/4� thick foam
Protip, don�t forget to install the thick foam gasket around the AC lines between the firewall and hvac box. Or else you�ll have to pull it all apart again.
Hats off to you and others who've gone all in to repair the HVAC foam issue. Outside of the enormity in tackling, my fear would be I'd get it together and introduce a squeak, rattle or some other sound that would drive me crazy. Lol.
Great job!
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