04 expy Rear AC noise

[keithnra]

when u turn on the rear ac there is a clicking noise coming from under the plastic on the right rear side and it doesn't g away.

 

[keithnra]

oh yeah the ac works fine, it just makes a noise almost like a relay

 

[keithnra]

I pulled the cover off the other day and there is a white rectangledbox with the wires going into it that seems to be where the clicking is coming from does anyone know what that is and why it clicks.

 

[96mustangV6]

There's a sticky on top of page that describes this problem. My 03 navi is doin it to. The gears strip out. I went to junk yard and got some more gears. The box cost me $12 at a pick n pull.

 

[96mustangV6]

http://www.expeditionforum.com/f41/popping-noise-rear-c-blower-03-expo-2324/

 

[keithnra]

What does the box control

 

[ExpeditionAndy]

What does the box control

More than likely it is the blend door actuator. It mixes the warm air and cool air to maintain the temp that you set on your temp selector.

 

[ExpeditionAndy]

You can get the whole assembly from an autoparts store. I heard prices ranging from $40 - $100. The dealer will be much more expensive and you will not get anything better than what the autoparts stores have.

 

[96mustangV6]

I just got the whole box from a pick n pull yard out of a 04 expy along with some gears out of a first gen expy. They are different boxes but SAME gears. So I have bout 6 sets of gears. The box ran me bout $12 cause they didn't know what it was under.

Took me bout an hour to change both. Did it just now and now no clicking sound. Yaaaay. Wife will be Happy.

 

[jdecker]

There are two actuators in the rear a/c one controls the vents floor/ceiling the other controls the temp blend. The easier of the two is the vent control unit located directly under the cup holder in the rear, this can be replaced by removing the cup holder and junk tray. The other unit is behind the rear quarter trim panel. Just pop the rear cup holder out and feel the white box located under it and see if it feels like the ticking is coming from that unit.
Also 96mustangs advice about the 1st gen gears can save you some money, I recently picked up six sets of gears at a u-pick salvage and was only charged $5.

 

[96mustangV6]

Yea the boxes out of 1st gens are different but the gears are the same. I just took the box apart and replaced the gears and greased them. Works like new.

Not a lot of pick n pulls had 2nd gens so I tried the gears and it worked.

 

[keithnra]

cool im heading to to he u pull it tomorow so i will try to get some gears

 

[keithnra]

I fixed one if them by getting the gears out of an older expy, it fixed one of them now I have to do the other one

 

[GAINMOB]

change both boxes as they control the blend door and high/low flow door...a little bit of pain to get in but will fix the prob...change both...change both...youre looking at $50 tops for both

 

[keithnra]

yes ijust have to make time to do it

 

[GAINMOB]

20-30 mins...and thats pulling the panel and replacing the panel