[BillC]

The air conditioning in my wife's 2007 Boxster S isn't working very well. I checked the refrigerant last night, and it reads good on the gauge. So, it's something more than just low refrigerant.

Can anyone recommend a good automotive A/C repair shop, somewhere in the central Maryland vicinity? Thanks!

[N0tt0N]

Bill,
Two questions:
1. Have you already had the grey foam bits flying out of the vents? These are a ridiculously stupid and 'known issue' for 9x6s they carried into the 9x7s whereby the Heat/AC flaps within the inaccessible HVAC box under the dash are aluminum with giant holes in them that are then covered in a light foam pad that begins to dissolve in exactly 15 years. Once enough has dissolved to uncover the holes there is virtually no ability to control the flow of air over the AC condenser. AC works as designed but no air is driven through the condenser so it appears to not work.

2. Check the codes as another 'known issue' is the fresh air/recirculation flap motor on the far passenger side of the HVAC box under the fresh air filter usually breaks (a little white gear inside really) around now. This is unlikely the culprit though it would degrade apparent AC if you can't recirculate air.

I'm dealing with both in my 2006 Cayman S as we speak and trying to decide if I'm interested in tearing out the entire dash to actually fix it or try some of the 'good enough' fixes that only require cutting into the HVAC box through the central dash behind the radio, etc.

[BillC]

Originally Posted by N0tt0N

Bill,
Two questions:
1. Have you already had the grey foam bits flying out of the vents? These are a ridiculously stupid and 'known issue' for 9x6s they carried into the 9x7s whereby the Heat/AC flaps within the inaccessible HVAC box under the dash are aluminum with giant holes in them that are then covered in a light foam pad that begins to dissolve in exactly 15 years. Once enough has dissolved to uncover the holes there is virtually no ability to control the flow of air over the AC condenser. AC works as designed but no air is driven through the condenser so it appears to not work.

2. Check the codes as another 'known issue' is the fresh air/recirculation flap motor on the far passenger side of the HVAC box under the fresh air filter usually breaks (a little white gear inside really) around now. This is unlikely the culprit though it would degrade apparent AC if you can't recirculate air.

I'm dealing with both in my 2006 Cayman S as we speak and trying to decide if I'm interested in tearing out the entire dash to actually fix it or try some of the 'good enough' fixes that only require cutting into the HVAC box through the central dash behind the radio, etc.

In answer to your questions:

1. Yes, we have been getting dark grey bits of foam blowing out the vents. Not a ton of them, so I'm guessing the foam has probably pretty much all disappeared. Your description of the issue fits the symptoms.

2. The recirculation appears to still work, since I can hear the airflow change when I toggle the recirc on or off.

More information about possible repairs would be greatly appreciated. When I built my Spec Boxster, the whole dash needed to be removed to pull the HVAC "suitcase" out; having to put it all back together again after repairing it would be a real nightmare.

[N0tt0N]

I totally agree with the PITA factor! Here is the beginning of the thread I was using to evaluate next steps. Since I have the broken recirc flap motor as well (which can technically be swapped out without removing the suitcase) I'm leaning toward the PITA option to repair everything.

https://986forum.com/forums/performa...nt-debris.html

[BillC]

I did some more searching, and found a number of videos about patching the mixing doors in 9x6 cars. But, of course, the 9x7 cars have different dashes, so you can't go through the radio hole in the dash like the earlier cars.

However, I did find a couple of threads where they pull the heater core to get access. I think this approach might work better, or at least well enough, for the 987.
https://rennlist.com/forums/996-foru...ntn-issue.html
https://www.planet-9.com/threads/rep...ousing.256800/


Also, just for giggles, I stopped in at the dealer on my way home, to get a quote on having them do it. Total before any PCA-member discount was nearly $7K, since they would completely replace the suitcase rather than repair the existing one. And, it turns out, PCNA has a suitcase sitting in the warehouse, so no waiting for shipping from Germany.

[hoophead]

Originally Posted by BillC

$7K

I fixed the blend door on my old 986 with a kit like this when I replaced the heater core:

https://www.amazon.com/PIT66-1998-20.../dp/B0D1QLMVZG

Just gorilla glued the plugs into the holes via the heater core opening, didn't remove the actual door. My fat hands fit easily. Seemed to improve the performance.

Never got around to the other flap that you get to via the interior vents.

[BillC]

Well, I did the flap seal repair (through the heater core opening) yesterday. However, it turns out that the flap foam was not the source of the poor air conditioning -- the foam had only just started to fail, and was still functionally guiding airflow. I also looked up through the fan opening at the bottom of the suitcase, and from what I could see, the a/c evaporator does not appear to be blocking airflow.

So, I need a suggestion for a shop to do further testing and diagnosis. Any recommendations? I'll take it to the dealer if there are no other options, but I'm sure they'll be pricier than a good independent.

[HoodPin]

SSI did a repair on our 986 Boxster. I'm not certain if they have a similar repair plan for the 987. Additionally, Rennlist (and maybe others) have some defroster vent inserts for those cars where the failed foam is causing windshield fogging.

[BillC]

Originally Posted by HoodPin

SSI did a repair on our 986 Boxster. I'm not certain if they have a similar repair plan for the 987. Additionally, Rennlist (and maybe others) have some defroster vent inserts for those cars where the failed foam is causing windshield fogging.

Whatever the problem is, it's not the foam -- see my above post, I did the foam repair already. That's why I'm looking for a shop the specializes in automotive a/c.

[Patrick3000]

Originally Posted by BillC

I checked the refrigerant last night, and it reads good on the gauge. So, it's something more than just low refrigerant.

Let’s go back to the beginning for a moment.

What exactly did you check and how did you check it?