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Old 06-21-2017, 10:45 AM   #1
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Foam parts blowing out of vents 2006 Cayman S

Is there any work around for this problem except for the $4800 evaporator box replacement but it will re occur? This seems like design flaw Porsche should correct on recall (like that will ever happen). Love my car but I can't stand being pelted by foam.
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Old 06-21-2017, 11:23 AM   #2
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Originally Posted by envelope57 View Post
Is there any work around for this problem except for the $4800 evaporator box replacement but it will re occur? This seems like design flaw Porsche should correct on recall (like that will ever happen). Love my car but I can't stand being pelted by foam.
The reason there won't be any recall is that they would have to recall just about every other brand as well.

Take it apart and replace them yourself, it is a common and cheap DIY project that does not require a new evap box.
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Old 06-30-2017, 05:00 AM   #3
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While it may be a "cheap DIY project" it's certainly NOT easy or simple! There is a long thread in the Boxster section (with pictures) that shows whats involved. IF you think you'd enjoy taking the dashboard apart then go for it. Otherwise hire someone and pay the huge cost or live with it. (I carry a tweezer in the car so I can pull out the larger pieces when they get caught in the vents)...........

But you are correct IT SHOULD NEVER HAPPEN and Porsche should have addressed ir years ago.
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Old 07-02-2017, 02:19 PM   #4
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I have 3 pcars. 996 and 986 both have this problem. Really aggravating. My 968 doesn't have the problem. It would be an easy fix were this to happen as the vents will come out easily. Thats always the way it goes. Ha


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Old 07-02-2017, 05:56 PM   #5
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Originally Posted by Rob175 View Post
While it may be a "cheap DIY project" it's certainly NOT easy or simple! There is a long thread in the Boxster section (with pictures) that shows whats involved. IF you think you'd enjoy taking the dashboard apart then go for it. Otherwise hire someone and pay the huge cost or live with it. (I carry a tweezer in the car so I can pull out the larger pieces when they get caught in the vents)...........

But you are correct IT SHOULD NEVER HAPPEN and Porsche should have addressed ir years ago.
(1) I have done several of these, it is both easy and simple, but perhaps that is just my view.

(2) Let's look at the perspective of Porsche fixing it: When the IMS failures occurred, and $20K engines became boat anchors, Porsche did everything in the power to avoid taking responsibility, and even continued that tact in light of the class action against them. And you expect them to take responsibility for some dried out foam that is more annoying than a real problem? Good luck with that...........
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Old 07-10-2017, 12:26 PM   #6
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There is an easier version of accessing the flap with the deteriorating foam.
If you Search ,you'll find it. The technique requires removal of the Steering Wheel and then some delicate surgery to some plastic part that obstructs access to the flap.
The flap gets recovered in 3M Flue Tape(Home Depot)
This will get you started:
http://986forum.com/forums/general-discussions/67109-small-foam-pieces-blowing-vents.html
http://986forum.com/forums/performance-technical-chat/42802-interior-vent-debris-post323947.html
https://rennlist.com/forums/996-forum/822434-air-vent-debris.html
Interior vent debris
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