Foam out of vents - phase 2

[CBN]

Hello All,

I have a 2000 Boxster S with Tip. Have had it from new. I followed rsfeller's instructions on how to fix the foam out of vents issue and re-doing the cold/hot air mixer flap. Thanks to rsfeller for a great writeup on that.

I did the repair about a year ago and it worked fine. As of late, however, I have foam pieces coming out of the vents again. I'm thinking it is coming from the two other flaps directing the air to window/dash/footwell. These flaps are located further into the HVAC box when accessing it from the heater core position as described by rsfeller. At the time, I did not try to get to them or to get them out but it looked, shall we say, not easy. Has anyone come up with a way to do a similar fix for those flaps?

Thanks in advance.

[Jinster]

Hello All,

I have a 2000 Boxster S with Tip. Have had it from new. I followed rsfeller's instructions on how to fix the foam out of vents issue and re-doing the cold/hot air mixer flap. Thanks to rsfeller for a great writeup on that.

I did the repair about a year ago and it worked fine. As of late, however, I have foam pieces coming out of the vents again. I'm thinking it is coming from the two other flaps directing the air to window/dash/footwell. These flaps are located further into the HVAC box when accessing it from the heater core position as described by rsfeller. At the time, I did not try to get to them or to get them out but it looked, shall we say, not easy. Has anyone come up with a way to do a similar fix for those flaps?

Thanks in advance.

So that's what's been happening to my car. I just thought a piece of foam somehow made it's way into the HVAC system when I was driving. :-)

[Claus]

I think this happens to many and it is great to get it fixed. I'm still hoping someone has found a way to address this.

[Loren]

Unless you want to disassemble the HVAC unit most folks just reach in through the pollen filter (fan off!) and pull out the loose pieces.