Picture this. It's Mother's Day and we're heading out to dinner with my wife, the honored guest, mother of my children. We don't take the 850 because my daughter blew the motor the day before (read about it on the AWD forum), so we're already in a fine mood. We don't take the S80 because my 945 is blocking its exit from the garage. So I suggest in the interest of time we pile into the 945 and get going.

It's a warm day so I pop on the A/C and crank the blower to "5". Maybe you can see where this is heading.....

We are met with a shower of black bits of foam. Ordinarily this would be funny, but this foam has a certain oily goo factor to it. Best thing is when it hits your clothes, it leaves a stain, especially on white fabric, the kind worn by my wife. That went over real well, not! So we jump out of the car, while parked in the street and start preening each other of the black flakes.

I had some experience with this foam last year. Thought it was under control. Now it has returned.

I've removed the duct grilles and used a vacuum to draw whatever is left in the bowels of the system. Still, the stuff continues to break loose sporadically. Today I removed two more pieces, each about 1" square, from behind a grille.

So what is the source of this stuff and how far in do I have to go to eradicate it completely?

regards,
Doug
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'94 945t; '95 854 base; '05 S80 2.5T