Ford Excursion :: 2004 - AC To Heater - Clicking Noise Behind Glovebox


Oct 12, 2015

We have a 2004 Excursion limited edition with 6.0 diesel. This is a recent purchase for our family. This is our first ever Ford and our first ever Diesel.

Now that we are transitioning into colder weather, we recently tried to place the air from AC to Heater. When we tried, we noticed a clicking or hitting noise from the passenger side behind the glove box. When we stopped the air, the noise stopped. When we kept it on the AC, it stopped. Last night we tried to replicate the issue to get more info and we saw that now its stuck on heater and we lost the AC cold air. The module that is making noise is behind the glove box. It is not coming from the actuator that moves air from the feet to the vents, but it is to the right of the actuator and has a plug with about 4 cables plugged into it.

Questions:

What is this module so that I can order a new one?

Does this sound like a bad HVAC blend door actuator? (not trying to steer it that way if its not.)

Any videos on how to replace it? I only see one bolt that mounts it and it appears to be about 8 mm. Is that the only thing holding it?

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YouTube .....

Before I spring for the Timkin, does this sound like a bad bearing? No play in the wheel, but it's a clicking sound.

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See photos ....

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Items Checked Or Replaced In The Last 4 Months ( trying to fix)

Tie Rods. Ok
ball joints. Ok
suspension front and rear. Ok
Front stabilizer bar. Ok
control arm bushings. Ok
stabilizer bar bushings Ok
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O ring ord part # 4C3Z-1K106-AA
(knuckle seal) (F81Z-3254-CB).
and some other dust seals which i can't recall.

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