[JFP in PA]

Originally Posted by iaincamp

Any ideas? (And, yes, its been blowing bits of foam in my eyes ever since I bought it, but I doubt the two issues are related).

Actually, they maybe related. These systems work by using doors that open and close to control both the flow of heated or unheated air movement, and these doors a sealed by foam rubber strips. When the door seals start falling apart, you can get exactly what you have described. The fix is realtively easy as the unit with the doors in it is under the dash on the passenger's side and drops straight down.