Insulation Foam out of A/C Vents!

[Nehmaiz]

03 C4S with 103,000 KM.

Hi Everyone, was wondering if anyone has experienced this problem before...

it's really starting to get hot around here (46 degrees Celcius) and about a month ago i started seeing small foam/sponge parts coming out of the A/C, and yesterday when i took the car to the track, the sponge particles were getting bigger and bigger getting out of the vents...

i can only assume these are insulation sponges that are deteriorating, do i need to replace them? i assume would be a costly and time consuming job... anyone had something like this before?

Thanks,

Nehme

Edited July 31, 2011 by Nehmaiz

[judgejon]

03 C4S with 103,000 KM.

Hi Everyone, was wondering if anyone has experienced this problem before...

it's really starting to get hot around here (46 degrees Celcius) and about a month ago i started seeing small foam/sponge parts coming out of the A/C, and yesterday when i took the car to the track, the sponge particles were getting bigger and bigger getting out of the vents...

i can only assume these are insulation sponges that are deteriorating, do i need to replace them? i assume would be a costly and time consuming job... anyone had something like this before?

Thanks,

Nehme

[judgejon]

Lots of posts on this. Check search engine for info. I believe it's foam from the heater/ac air mix flap.

[Lee Quave]

I’ve been having the same issue. It’s been going on for over a year. I’m not sure if the foam in the ducts causes it but when I have my AC on (9 months a year) my windshield gets foggy strips along the bottom but if I turn on the floor vents it doesn’t.

It would be great to find out what causes this and how to fix it.

[JO2004c4s]

OK>>>Hi This is my first post.  I have started the process of addressing the "foam from vents" issue.  Some helpful links and notes...

 TO remove dashboard...this forum was a huge help where I found some links.  I'm just not sure they were all together...

 

To Remove Dashboard:

 

Comment: Perhaps I over looked, but the AC Evaporator will be disconnected..gas will leave system...It will cost about $200 to have it recharged....get new o-rings, pressure valve, Evaporator and Drier (these part are about $150); Also I could not remove my heater core without bending metal from reinforcing braces.  I was removing blower box so it doesn't matter.  I will also replace heater core (approx $125).  I'll also replace blower...(3 options  original $500, German Made $240, other $100...I opted for German but my blower seems ok so I may send back)

 

Removing blower box was not fun!  Removed wiper motors/arms to get to nuts on firewall.  Removed alum structure on driver side to remove more structure in the radio area.  

 

I did not use this approach but it's a good link.  I am opting to use a scotch-brite pad in place of the foam.  The grey dense one.  I am also going to screw and use a small thin aluminum strip to hold the pad of the flaps.  Pay attention to weight and mass.  I just did't want to deal with tapes and adhesives.  

 

 

Link to MY PICs

 

Updated Link 12/4/18

 

Amazon Photos

WWW.AMAZON.COM

 

NOW...I am investing into the car as well.  I am redoing some of the Leather dash.  Putting a suede on the A-Pillars and top windshield screen.  Adding some to doors as well.

 

 

AC has been charged and it's going back together.....

Edited December 4, 2018 by JO2004c4s

[AVSZOOM]

Where can I find the actually procedure to replace/repair the foam shooting out my AC vents on 2004 Porsche 911?

[DBJoe996]

Welcome to the world of older 996's.  Mine is a 99 (made in 98) so I am familiar with the foam issue.  Been there, done that.

You have three options:

1) Live with it.  Eventually it will stop.  When mine did this, I took a shop vac, put the fan on high, and started cleaning it up.  Tweezers help pull out the bigger pieces. I did this several times over a span of about 6 months, and then it stopped.  Been over 8 years since I have noticed any foam.  Thing is I have noticed no difference in the heating and cooling.  Still works great.

2) There is a method/procedure for entering the air box by removing the heater core from outside the cabin.  This is complicated and some parts need to be cut, and it only gives you access to one of the flaps (there are three).  Some say this works, but for me it is just not worth the hassle.

3) Remove the entire dash and all electrical connections to be able to remove the air box.  The air box is sealed so you will have to find a way to cut it open so you can put it back together.  You then can replace the flap door foam with new foam (not a good idea) or use metal duct tape, or fashion new flap panels from metal.  You could replace the air box ($$$) but after a few years it will only start doing it again.  There is a lot that can go wrong with removing the entire dash.  Again, just not worth the risk or hassle.

 

As I stated, once my foam stopped coming out, I have noticed no change in how the AC and heat work.  Nice and cold on warm days, and nice and warm on cold days.

Edited September 12, 2019 by DBJoe996