Fan AC Noise Behind Glove Box (with video)

[mypctechs]

Yesterday morning my 2003 Porsche Boxster started to make a loud and hard to describe noise (is it rumbling or buzzing or lawn mower?).

The noise happens with the engine on or off whenever the fan is blowing air through the ac vents. I've tested and it makes the same noise whether the AC is on or off, so it must be the blower? It also makes the noise whether I have it blowing hot or cold air.

Interestingly enough the AC continues to work and gets cold, but I'm a little concerned that it's going to break down soon. The sound is coming from behind the glove box on the passenger side.

Thoughts on what this could be? I have an oil change scheduled and want to know what I'm dealing with before I get it inspected.

TIA!

Edited August 10, 2012 by mypctechs

[1schoir]

If it only makes noise when the fan is blowing (i.e., when you have selected one of the blower speeds), and stops when you turn off the fan, then it's your blower motor/squirrel cage that is making the noise.

I could be the bearing in the blower motor or something more simple, such as something having gotten dislodged and rubbing/being hit by the squirrel cage as it spins.

Although you have to get in a contorted position, you could get under there with a light and have a look or feel under the dash, directly above the passenger's feet.

Regards, Maurice.

[Richard Hamilton]

You could also try taking out the pollen filter, and see if you can look inside for soething in the fan housing.

[mypctechs]

Well, it definitely was an unusual problem causing the noise! I'm happy to report that Renntech helped me FIX this issue!

Thanks 1schoir! After reading your post I did a lot of research looking for information on blower, fan, blower motor.I felt it was the blower motor since it got louder and softer as I turned the velocity of air up and down. I eventually came upon a bunch of posts dealing with foam getting stuck in the blower motor, here are a few choice selections:

http://www.renntech....lap-flap-noise/

http://www.renntech....nside-the-dash/

I even found a pic of the blower motor:

http://www.pelicanpa...tion_red_on.GIF

I thought I had the same issue as the other posters and there was foam stuck on the squirrel cage, so I took apart the pieces under the front hood on the passenger side. First I revealed the cabin air filter, then I removed it, and I saw the squirrel cage. I took some pics along the way.

For anyone else like me who comes along and is having this issue, here's what the pictures represent and how to check this:

1. Top/right in front of the passenger dash is where you find the pollen filter. It's easy, open the hood, take off the plastic pieces / grill protecting the top using a wrench

2. You will see the area where the cabin filter is, it's easy to remove (already removed in this pic) just gently slide the cabin air filter out from the slot

3. Deep inside of this hole you can see the squirrel cage that matches the pelican parts pic I linked above. It's down through the hole past a large plastic flap

4. You can turn the cage to inspect the blades. You can see in pic 4 a dark mass on the blades, THAT is what was causing all of the noise!

Instead of finding a piece of foam in there as I suspected, I actually found a piece of electrical tape that was stuck pretty tight to 5 of the blower cage blades. I have no idea how that got in there past the pollen filter but it did!

As soon as I pulled the tape out I was good to go! If you find something in there and plan to pull it out, as others have said in different posts, make sure the car is off and the fan is not running before you stick you hand down there!

So Richard you were dead on with the cause as well. Any ideas on how a piece of electrical tape could have found a way into this area?

If it only makes noise when the fan is blowing (i.e., when you have selected one of the blower speeds), and stops when you turn off the fan, then it's your blower motor/squirrel cage that is making the noise.

I could be the bearing in the blower motor or something more simple, such as something having gotten dislodged and rubbing/being hit by the squirrel cage as it spins.

Although you have to get in a contorted position, you could get under there with a light and have a look or feel under the dash, directly above the passenger's feet.

Regards, Maurice.

Edited August 11, 2012 by mypctechs

[1schoir]

:cheers:

Regards, Maurice.

[Richard Hamilton]

Glad it was an easy fix. The pollen filter isn't a great seal on the housing, so maybe someone put some tape around the opening to try and get a better seal at some time.

[Gabriel Dufresne]

instead of starting a new thread about it, i'm gonna revive this one.

i'm trying to reach the ''squirrel cage'' as it's shown in the pictures above. my problem is, the ''flap'' is on an horizontal position and won't rotate so i can't even reach or see the squirrel cage.

i don't want to break it by forcing it to rotate, so do you guys knows the right way to rotate the flap?

thanks!