Re: 2003 Expedition 5.4 Rear AC problems
Wow you guys saved me from pulling alot of hair out today. I had been having the same problem with my 2003 EB Expedition. I had an extended warranty that I thought covered bumper to bumper (b/c as I told the guy when I bought the car I want coverage for all the electronics and gadgets on it). Well it wasn't covered and I was p*ssed! They told me $425 and two days to change out both actuators.
What I found out was this was $100 in parts and $325 in labor. Thanks to this and another forum I was able to get the parts out and installed in under 2 hours. That is a hefty labor charge for something I can diagnose and fix myself with no prior knowledge. No more trips to Joe Myers Ford for me! I guess since this was my first trip it is no loss to them though.
Anyway here is more of what I have learned. The vertical one that sits on the outside adjusts the temperature. Mine would click when you adjusted the temp, but if you put it at certain levels it would completely stop clicking. This part was $68 (p/n YL5H-19E616-AC) and required me to remove the back seat and loosen the back panels to replace. I took the old one apart and could see that the small gear had lost 50% of it's teeth.
The other actuator that sits flat and up higher can be removed and replaced by simply removing the cup holder and the upper tray. Unfortunately that was not the culprit in my case. All the teeth were in good shape, and for some reason this part is only $32 (even though both parts look 99% the same). This is the AC Door Actuator and adjusts whether the air goes to the feet or to face.
I would highly recommend fixing this yourself if you are mechanically inclined in the least. With what I have learned I think you can diagnose which one is going out depending on if it is affected by the temperature adjustment or the air flow adjustment. One other thing of note is the temp adjustment one that I fixed is evidentally more common, and the clicking will persist even when the A/C is off (although on mine it was much quieter), because for some reason this motor runs all the time.
Thanks to all previous posters. You saved me $350!