The hvac case was inadequately designed so that the mode door could not contain the Blower cfm's at high fan speed.
This causes a fluttering mode door and the obnoxious sound that goes with it.
The solution was to ADD little foam blocks to hold the mode door open further than it's normal leak rate, so it wouldn't make the flutter sound at high fan speed.
Then, more complaints about air on windshield.
Ineffective TSB was released to remove added foam blocks, and reprogram BCM to lower fan speed cfm for high speed setting.
The mode doors still leak.
Door needs more foam weatherstripping. Might be able to get the actuator to pull it tighter.
Poor visibility through the windshield is not only maddening, it is an outright safety hazard.
I'm going to check this BEFORE taking delivery, and will NOT buy ANY car fogging (inside) and causing blinding condensation (outside) on its windshield.
Put a little more foam on the MODE door.
v
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