I don't know if any one else has this issue of foam coming from the vents. On my 2010 RX350 I noticed pieces of foam coming out of my AC vents a few weeks ago, and have now had the time to investigate. Found out that the foam is around the baffle inside the vent that allows it to be shut off. My wife has recently been shutting hers off on the passenger side. Now I can see chunks of it missing around each vent that she tuned off and back on. I would have liked to have had Lexus use better materials, but am not going to worry about it; it's not worth the expense and time of replacing it. I will just deal with a little air coming out even with the vent tuned off.

 

All duct work is plastic and when two ducts meat, Lexus uses foam packing. As the foam ages it starts to break apart and the piece that are in the flow get thrown out towards the vents. Use tweezers or suction. Don't be too aggressive as your intention is to pickup and not tear.

Salim

 

I wish it was that, it would be cheaper to fix if necessary. But I don't think this is my problem. I pulled out one of the vents and took a picture from inside looking out. I can see the foam on the top of the baffle that closes off the vent, but on the bottom and a small part of the side it is torn away. I found out that if you even get close to touching it, it disintegrates. I guess it wasn't made to last. The only problem with this is that now when my wife doesn't want any air blowing on her, she can't completely close off the air vent.

 

If it does not close all the way, you can try to redirect it.

If some one is crafty, they can remove the old foam and create a new one with foam or felt.

Salim

 

Thanks for all the Advice Salim. I will probably at some point try to get some foam or felt as you suggested, and try to take it apart.

 

I should have put a smiley on my reply. Glad you were not offended with the reply about redirecting the vent.

There is a classic solution to noise in a vehicle .... turn up the stereo.

Salim