Pieces of foam in AC vents and on the floor

[John Kelly]

I have a 2004 C2 CAB with 120K miles.  I am getting bits of black foam material coming from the air vents and from under the dash.  Where is this coming from? and how can I fix it?  I was told there is a foam "pad" on the air flow box under located under front hood near battery.

[DBJoe996]

The foam is from a flap inside the air control box under the dash or some lining in the vents.  This is a very common problem.  It is a difficult and PITA job to get to the flap, and you cannot just order a new flap.  What most have done is vacuum up the mess, keep a pair of tweezers in the car and pull the stuff that gets stuck behind the vents, and wait patiently until all the bits and pieces stop coming out.  That will happen.  Mine did this a few years ago and it was definitely annoying.  But after research decided to wait it out.  Funny thing is, I've never noticed any difference in the air flow/direction to the various outlets since.  Seems to work just fine without whatever that foam on the flap is for, or the vent work linings.  Actually has been a long time since anymore came out, so I figure problem resolved.

 

BTW, there is a pollen filter located just where you said, to the left of the battery.  Should be periodically replaced. Doubt that is the source of your problem unless it is old and very deteriorated.

Edited December 27, 2016 by DBJoe996