Turned the front defroster on the other day and was showered, more like pelted, with small bits of foam. Then it started blowing out the vents and I see large chunks that will never pass thru unless I pull them out. I did a search and found thats it not uncommon, however, I now have a rattle coming from the dash which Im assuming is the blend/temp door vibrating on what use to have foam on it. It rattles less with the heat on, but either way any road imperfections and it sounds like a can of pennies.

I can live with the foam, but the sound is keeping me from driving it. Anyone have any solutions or suggestions to resolving the problem, besides removing the dash?

Thanks
Scott

 

thought i'd heard it all by now.. but foam!? wtf is that? did your pollen filter explode?! sounds awful.. good luck with it.

 

Not uncommon? I've been on this and the other sites since 07 and have never heard of this before. Any idea what the foam actually is?

 

Never ever heard of this, and yet very interested to see what went down. Good luck and keep us posted.

 

Mice eating your car from the inside out?

 

it just occurred to me. i believe there is foam ( or foam can/has been used ) to combat rattles behind the dash. my last car had a rattle and the tech ( who probably lied ) told me he did something w/ some foam behind the dash to minimize a rattle. it's like 4 years ago car so my memory of the event is hazy, but that doesn't begin to explain being "pelted". wtf.

 

Same thing on my wife's 996 but without the noise. I fish out the foam chunks with a pick .

 

I know they use foam around most of the heater duct junctions to prevent rattles and air leaks. The foam around the blower motor is probably crumbling and getting kicked around by the blower motor. Your best bet is probably going to be to remove the dash and put new foam around it.

 

From what I've read, I need to pull the battery and see if i can get to the blend door thru the heater core. If it turns out not to be reachable from there ill probably leave it since I don't want to pull the dash out. Wondering of this would be covered by my extended warranty?

 

kinda doubt it. tough for the shop to sell that as a coverable item repair. i would think. but ya gotta try.

 

Warranty is probably not going to cover anything. I would first pull the pollen filter out, then look down and see if anything is visible in the blower area from the pollen filter housing. This is really simple, and a lot of people have found weather stripping and other stuff vibrating against the blower motor this way.

 

Thanks for the ideas. Looks like tomorrow I may have the time to dive into this. Hopefully it will be easy to reach and fix as the rattling noises are killing me.

 

Were you able to figure out and then resolve this problem. Chunks of black foam started blowing out of my vents today and I fear that the insulation/stripping inside the vents is starting to disintegrate. I really don't feel like trying to replace my a/c vent tubing.

 

I got a 987 boxter 2005 i got the same problem lots of black foam come of the vents

 

Same with mine foam coming out everywhere. This sucks!!!!