66Fastback

Pop out the cup holder, and the other holder just behind the cup holder. This will allow you to see quite a bit in there, and you can pull the panels off easier. All the panels just pop out, but there is one plastic screw in the floor board underneath the popup hatch that stores your jack. All the side and roof panels just pop out. It takes a little work and patience, but it goes back together very easy. It took me about an hour to figure out how to get the seat and panels out, but about 20 minutes to put it all back together.

Hope this helps. It is hard to describe, but after you pop off the first few pieces it is much easier to see how it is all held together.

 

andy b

FWIW, I have the 03 Expy with continuous rear air unit "clicking" or more accurately flapping of the air damper while the plastic gears in the 2L2H-19E616-AA grind away into toothlessness. Ford designed this unit to find the end of travel by jamming the motor to a stop and monitoring the current to determine when to stop applying voltage. That would probably be fine if the gears were designed to handle the jammed torque or the motor did not slip out of groove and continue turning and cracking the plastic gears. How can Ford continue to provide its customers the pleasure of paying for this obvious design defect? I guess those without conscience get away with what you can when they can.

The rest of the rub is that the two gears that get chewed up cost WAY less then $1. I think that most of you know how much it costs to replace those $1 parts. THANKS FORD!

lawsonsamuels

Wifes Expedition, 2003, is doing this exact thing. But hers makes the noise even if I turn off the main controls in the front. By either turning the controls to allow rear control and adjusting temp accordingly or making it blow on 3 and adjusting temp from the front overhead control, I can make it quit. But then when I cut off the whole A/C system it starts back up.

Do I have an electrical issue along with the blend door issue?

66Fastback

Most likely not, but I can't guarantee anything obviously. Mine did the same thing which really confused me. When off it would make the noise as well. I believe one of the actuators stays on all the time. Most likely you have the same broken one as I did (the one that costs double the price and is much harder to remove and install). It is still an easy job. I would suggest opening the actuator after taking it out and see which one has broken gears and only replace that one.

This definitely fixed mine. I haven't had a click since when I posted the original message I did. Good luck.