Foam coming through my air vents!?!?!

[Dgrange]

I have small pieces of black foam blowing through my air vents, Any idea where it's all coming from or how I can clear it all out. Little bits of black foam flying at me when driving is becoming a huge pain in the ass!!

Help!!

[shadrach74]

This is likely the foam gasket material used in the HVAC system to seal the various "flap" type doors that open and close to divert blower air from your feet to your dash vents to your defrost vents. Not much you can do short of opening up the system. The good news is that at some point it will stop... the bad news is that the doors in your HVAC system will no longer have gaskets to seal against.

There are a couple of other place it may be coming from. I would pull the filter and housing and see how it looks. The filter housing is under the bonnet on the pax side.

Pelican Technical Article: Boxster Air Filter / Pollen Filter Replacement - 986 / 987

[Dgrange]

Great, thanks for the info.....sounds like a night in my garage tomorrow night!

Thanks again.

[RandallNeighbour]

Many of us complain about this. A typical problem with older boxsters. I thought mine would run out of foam bits spitting at me and collecting on the floorboards, but it's been doing it steadily for two years now.

I guess I need to tear off the dash screw by screw, find the rest of it, remove it, and replace it all.

Sounds like a good time to send the dashboard off for leather to be added to it, huh!

[Dgrange]

Thanks - I may be able to give you a run for your money on putting $$$$$ into these cars, I have had mine for 14 days and by Friday will have spent over 4k!!!!

Unbelievable! But still live it.....

[shadrach74]

Originally Posted by Dgrange

Thanks - I may be able to give you a run for your money on putting $$$$$ into these cars, I have had mine for 14 days and by Friday will have spent over 4k!!!!

Unbelievable! But still live it.....

This is a story that I'm sure we'd all love to lean more about!

[Meir]

The full solution:
A/C evaporator replacement-A/C foam flakes

[tanque55]

The foam coming from your AC vents is a common problem on older cars. As the rubber and foam gets older it starts breaking down, specially in warm climates. Without tearing the dash apart not much to do about it.

[thom4782]

Keep searching the forums. There is a procedure to R&R the foam without removing the dash and opening up the air handling box for the heat and AC. The fix involves removing the heater core, but I don't remember off the top where to find the post.

Found it: http://www.renntech.org/forums/tutorials/article/121-fixed-my-lack-of-heat-problem-here-is-the-procedure/