http://expeditionforum.com/showthread.php?t=2324
Some quick pointers:
-switch the floor/roof position knob. If the clicking pauses then resumes, then it's the motor that's accessible from the top tray.
-switch the temperature from full hot to full cold. If there is a pause, it's the temperature blend motor, and you'll probably have to remove the whole rear quarter panel, unless you have very long, skinny hands.
-whichever one it is, you can stop the clicking sound by unplugging the motor, though you will no longer be able to control it. You'll have to "time" the door to whatever position you want it to stay in when disconnecting, unless you take out the motor and manually set it, then leave it disconnect it (though at that point you might as well replace the gear/whole unit
).