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I had this problem and did the DIY that was refereed to above. Pretty straightforward. Mine has been fixed for almost a year and a half now and I still have this crap coming out of my vents. I took as much as possible out from the heater box, but I guess some pieces were already in the vents.
I sealed the flap with some metallic tape and then put weather stripping around the edges, followed by another layer of metallic tape. The hot/cold function works very well....I just have to deal with the remnants of that black foam junk for now.
I hope somebody can provide that DIY, it was very well written.
SB
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