Re: Small bits of grey foam material out of air vents.

I have noticed lately small pieces of what looks like a light foam material, grey in color, coming out of the vents occasionally when I have the heater/AC blower running. Is this part of the particle filter, (996 572 219 01), that has come loose or some other issue? 1998 Boxster.

to check. Have a new one ready to replace the old one.

However, the charcoal layer is not in any foam format.

There is IIRC a strip of dark colored foam/sponge around the filter to help effect an air seal of the filter in the housing/holder. If it is this you see then the possibility of rodent infestation becomes more likely.

If you find the filter intact what it is probably from is from vent insulation. I do not know what the solution is in this case, how to get at it to remove it and if it needs to be replaced or if one can do without it with no negative side effects.

... all Porsches will spew this sticky grey foam.
Depending on the actual conditions of where you live (temp/humidity) it will start right around 10 years (humid and hot) or later (cooler and drier).
Once it starts it can take up to one full year for all of it to come out.
The source are the air managing flaps in the air handler of the HVAC system.
Nothing to do other than use a vacuum cleaner and a pick ... and don't wear white
Happy Boxstering,
Pedro

Pedro Bonilla
1998 Boxster 986 - 311,000+ miles: [www.PedrosGarage.com]
PCA National Club Racing Scrutineer - PCA National HPDE Instructor - PCA Technical Committee (Boxster/Cayman)

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Thanks to both Pedro and MarkW for their posts. What Pedro describes is exactly what the problem is. A fixable Boxster problem without the layout of a bunch of money. Wow!