Every once in a while small pieces of grey foam rubber blow out of the dash cooling/heat duct. I tried to see where there might be coming from, but can't see anything.

I don't hear any rattle or noise and everything is working fine. Before I bought the 2007 Jag 3.0 S Type 6 weeks ago it did have the cabin filter replaced & I don't know if that's the problem.

Unfortunately it usually blows out on my wife who is still not happy with my buying the Jag. Maybe it's the car's way off getting back at her.

 

ha, i find this humorous.
the foam is used to seal the joins in the pipe work/ducting.
something may have been refitted incorrectly , resulting in sheering the foam off whilst
sliding the ducts back together .
or the foam is rotting . obviously it will eventually stop doing it when the foam runs out of a supply . but that will result in a well ventilated inner dash cavity .

 

Unfortunately, this is a normal occurrence for the gradually-deteriorating foam insulation inside your HVAC ducts. The crumbled foam falls down into the ductwork then gets blown out into the cabin by the system fans. This eventually happens to many older vehicles, regardless of make, and your blowing debris may diminish somewhat over time. The good news is that the HVAC system typically continues to function normally even after most of the foam insulation has deteriorated and blown away....

 

Thanks guys!