Interior vent debris - 986 Forum - The Community for Porsche Boxster & Cayman Owners

grc0456 · 11-22-2015, 04:23 PM

to perform the DIY. Took my quite a while to get to the point that the mixer door was out of the car, but I got there. Re-foamed and taped up the door. Putting it back in was very difficult for me. To get the little bushings under the door axis caps on both top and bottom was super tricky. After some cursing and blood, I thought I had every thing back together in order.

Alas, when I started the car up and brought it up to temp for the all-important test of my not too handiwork.......it blew cold air

Not even luke warm like before. I could hear the servo motor moving (or trying to move?) the door when I changed the temp on the dash control unit. Any ideas before I admit final defeat and take her to the dealer?

I did take some pics that I hope can be of help to others.

Meir · 11-23-2015, 07:59 AM

do you have a picture of the re foamd flap back in place?

grc0456 · 12-01-2015, 02:26 PM

I have heat! Now measures 124F when at running temp on HIGH.

The DIY would have worked if I was a little more patient or skilled. The bushing at the bottom of the mixer door axis was cracked, causing the door not to pivot when activated by the servo motor. Not sure if I damaged it during reassembly (it was very tricky to remount the door), or if it had been broken all along. The problem area is located under the circle accessed from the under dash in passenger footwell:

The indie was able to repair the bushing - hopefully - for a long term fix. They had never heard of this foam/mixer door problem, so they learned something. Maybe because it is not as common in colder climates. My car was born and raised in FL. Cost was 4 hours labor.

Meir · 12-04-2015, 06:08 PM

Glad to see you sort it out.
:dance:

grc0456 · 12-05-2015, 01:23 AM

Quote:

Originally Posted by Meir

Glad to see you sort it out.
:dance:

LOL, yes! The indie sorted it out for me for $400. Oh well, like you said - try it myself and if it fails then - I was going to pay anyway.

But seriously, I feel like I learned a lot about the car and, actually, the indie learned something new too. They had never seen this problem before as I guess the foam doesn't deteriorate over time up north like it does in the south.

Thanks for your help, Meir!