996TT Foam breakdown in HVAC System?

[craig.wilson1]

I'm wondering if anyone else has experienced an issue with foam particles/chunks coming out of the HVAC Vents. Please see the picture. Any advice?

[JFP in PA]

Yup, and the topic has been discussed about a million times……search is your friend

[craig.wilson1]

Got it, foam seals. I sometimes find that the quality of information from searches is highly dependent on the choice of keywords. It can often become a time-consuming research project to find relevant information; lots of chaff, little wheat...

[rfuerst911sc]

Do a internet search of " porsche 996 blend door repair " . There are tons of DIY info on Rennlist 996 forum that will come up . Read them and watch the videos .

Basically there are two blend doors . One controls heated/cooled air the other controls where that air goes defrost/dash/floor . Those doors are made of aluminum and have round and rectangular holes in them . Porsche covered the doors with sheet foam .

That foam breaks down and starts coming out the vents . When enough foam has failed the systems ability to control things is greatly diminished . Sometimes to the point that you won't get heat or AC even though the system is working .

One door is accessed from the frunk the other from behind the radio . Some folks say you can do both doors from either location but you need hands the size of a 2 year old . Most shops ( not all ) will say the dash has to be removed to make the repairs which is big $$$ . Good luck with your repair

[jchapura]

Originally Posted by craig.wilson1

Got it, foam seals. I sometimes find that the quality of information from searches is highly dependent on the choice of keywords. It can often become a time-consuming research project to find relevant information; lots of chaff, little wheat...

I haven't done this repair on my 997.1 yet but here's a link to a seemingly great thread:
https://rennlist.com/forums/996-forum/1183277-repairing-the-iblack-foam-coming-out-of-ventn-issue-4.html

[craig.wilson1]

Thanks for the additional references, lots of great information out there.