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I had noticed the additional inaccessible blend door with the same problem and just left it as it was. Thought it would prove too difficult to try taping it while still inside the duct. As for the top of the pivot point, I left that hole there, too. It was in a covered area that won't be seen. After I buttoned everything up I thought I should've maybe taken a small black PVC cap from Home Depot and made some cuts to fit over this hole with some adhesive to give it a cleaner appearance, so that's an idea for you to try. That's more than likely what I'll attempt if I ever get back in there. Hope the rest works out fine for you.
So I was able to get the job done, but not without some hiccups. I couldn't "easily" access the servo arm underneath the glove compartment so I figured I had to remove the carpeted subwoofer panel that is attached to the center console along the left side of the front passenger footwell. I could see one bolt closest to the firewall but couldn't find the other. Had to look deep into the service manual to find out the other bolt was buried underneath a flap in the carpet. I eventually managed to successfully remove this subwoofer without damaging it and was then able to "easily" access the servo arm. I also learned that adjusting the temperature control switch from the console would position this servo arm to expose the head of the hex screw for removal. This job took me well over the 3 hours that it took rsfeller, but I got it done through his ingenuity and and detailed instructions - thanks! One additional note: when I removed the blend door that had the holes in it, I noticed another door deeper in the air duct that also appeared to have the foam blown off. It was completely bare and completely inaccessible via this method. You can see this other door in the video I posted above. That's what prompted me to look for it in the first place. I hope this resolves my poor temperature control issues. Thanks again to all!
Pete Agosto started following Fixed my lack of heat problem (here is the procedure)
Guys, I'm new to this entire Renntech forum. Found this thread due to experiencing this same problem - foam in the air ducts. This has been VERY informative, so I'll give it a try to see if it's possible executing this procedure in my 2004 996 CS4. For those wanting more information on how to seal the blend doors, I found this Youtube video of someone doing just that on a VW TDI. The doors and entire system look identical to what we have in our Porsches and the process looks easy enough. Just need to access the door(s) to get the job done. I'll update this post if I experience any issues. Thanks for your very informative posts!