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The foam in my 2006 F150 ducts jammed up my moade door. I got it out and wanted to replace the ripped up foam (probbaly similary to what your talking about). I went to the dealer to get a new piece and unfortuantely the foam is part of the next higher assembly, meaning you have to buy a $100 duct to get the foam!
I said no to that and I just improvised my own seal by using the felt side of velcro to make a seal. Umm, you could also try to use headliner foam and glue it on using spray adhesive, thats what I was going to do orignially but I couldn't access the ducting to spray on adhesive...........
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