I may have missed it but what grill is that? What lift did you use? I too feel like your Expedition is awesome so far and I look forward to the rest of your build!
I had this same problem recently on my 2010. I took it to the dealership because it was only a couple of days after buying it. They diagnosed it to be the blend door (electric motor with gears. The housing tends to separate over time and causes the gear teeth to misalign and click as they skip...
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