I too remember some years ago when black to dark gray foam pieces came out of the heater/defrost vents. I'm also sure it's not the heat from the floorpan. You can feel the hot air coming through the center floor vent.
I am currently working on putting in new carpet (Removed: 1st layer was jute padding down on the floorpan with a thin layer of a clay/tar type material on the top side but was all one piece. The passenger seat and rear floorboard also had a layer of pure white padding, and the carpet had a padding attached that looked like the outside fibers of a coconut that were pressed together.), headliner, and some re-painted plastic panels so I have not put back the right kick panel. Is that the vent door you're referring too? What type of foam should I use?
I'm not sure what it did when the Top lever is set to Vent and the Lower moved all the way to cool. It either put out warm air OR outside air did come through the dash pannel vents and hot air came out of the center console floor vent. I believe the only way to stop it was to run the AC.
Thanks again for everyone's help.