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Foam out of vents - phase 2


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Hello All,

I have a 2000 Boxster S with Tip. Have had it from new. I followed rsfeller's instructions on how to fix the foam out of vents issue and re-doing the cold/hot air mixer flap. Thanks to rsfeller for a great writeup on that.

I did the repair about a year ago and it worked fine. As of late, however, I have foam pieces coming out of the vents again. I'm thinking it is coming from the two other flaps directing the air to window/dash/footwell. These flaps are located further into the HVAC box when accessing it from the heater core position as described by rsfeller. At the time, I did not try to get to them or to get them out but it looked, shall we say, not easy. Has anyone come up with a way to do a similar fix for those flaps?

Thanks in advance.

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Hello All,

I have a 2000 Boxster S with Tip. Have had it from new. I followed rsfeller's instructions on how to fix the foam out of vents issue and re-doing the cold/hot air mixer flap. Thanks to rsfeller for a great writeup on that.

I did the repair about a year ago and it worked fine. As of late, however, I have foam pieces coming out of the vents again. I'm thinking it is coming from the two other flaps directing the air to window/dash/footwell. These flaps are located further into the HVAC box when accessing it from the heater core position as described by rsfeller. At the time, I did not try to get to them or to get them out but it looked, shall we say, not easy. Has anyone come up with a way to do a similar fix for those flaps?

Thanks in advance.

So that's what's been happening to my car. I just thought a piece of foam somehow made it's way into the HVAC system when I was driving. :-)

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  • 2 weeks later...

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