2004 Dual Climate Control Click and Thump Under Dash

[Kenerator]

Hi everyone! I am hearing a clicking and occasional light thump under the dash. This only occurs is the temperature is change from hot to cold, or cold to hot. Most of the time the sound stops after a minute or so. Does not occur when the any vent selection change is made. I can switch it from vents to floor to defrost to AC to recirculate to Auto to manual and no sound. Change the temperature, and the sound occurs.

I have replaced the blend door actuator on the top of the HVAC, but it did not fix it.
I have the dual climate control, so based on what I've read on here so far, I may have two blend door actuators - a driver's actuator and a passenger actuator. I have searched all over the internet for diagrams and/or fix information, but have not been able to confirm.

So, does anyone know if there are in fact two actuators? If so, are they the same part#?

Is this the driver's side actuator?



Thanks is advance for any assistance or insight!

 

[AWAR]

 

[AWAR]

On the dual control ac units the passenger side blend actuator is on top and can be replaced with the dash in the car. The drivers side blend actuator is on the bottom of the hvac box and the dash has to come out as well as the hvac box. Number one is the passenger side and number 4 is the drivers side. Below

 

[AWAR]

 

[Kenerator]

On the dual control ac units the passenger side blend actuator is on top and can be replaced with the dash in the car. The drivers side blend actuator is on the bottom of the hvac box and the dash has to come out as well as the hvac box. Number one is the passenger side and number 4 is the drivers side. Below

Thanks AWAR! When you say the dash has to come out, do you mean the dark section around the gauges and stereo, or do you mean the whole dashboard (the tan part)?
Also, how long and how difficult it it to remove the HVAC box?
Thanks!

 

[AWAR]

The complete dash then the hvac box. Discharge the a/c and all that entails. It is a real pain and a long process.

 

[Kenerator]

Dang. Thanks.

 

[kep5niner]

It’s not that complex, nor required the entire dash or the airbox to be removed. You have a blend door actuator up top, and a mode select actuator (IIRC) on the bottom. I’ve personally replaced them both.

The blend door actuator up top can be done in about 30 minutes. Ford Tech Makeyouloco has a great video on it. You’ll need a ratcheting-wrench, 8mm if memory serves me.

Replace with quality Motorcraft parts. You won’t want to have to do it again after the Dorman parts fail. It’s really not that bad. Good luck.

 

[whtbronco]

Well it's my turn to replace the lower front actuator. I'm gonna try to do a little write up with some pics to help in the future. I have everything out except 1 screw. It appears the lower/floor duct needs to come out and there is 1 screw in the middle in the back holding it to the plenum that I cannot get to. Once that's removed it looks the actuator will drop out and maybe this job can be done without removing the dash and discharging the A/C. It's like 8" from either side, but access is really only possible from the passenger side. I have my borescope in there so I can see. I can get my 1/4" ratchet on the bolt, but then I can't turn it.

@kep5niner how did you manage to get to the screw in the middle back that holds the floor duct to the plenum?

 

[whtbronco]

I got that screw out, needed a long thin 1/4" ratchet to reach it and even then it was a struggle. It's not a very impressive ratchet, the 72 count tooth kinda sucks, but it does have a locking flex head and it got the job done. It's 12.5" long. My longest 1/4" ratchet was 7". The only wrench I have that would reach it my offset 8mm wrench and would just barely reach. Despite it being a 12 point wrench I got it on and loosened, but could not get it on and able to turn it again.

81030 1/4" Drive 72-Tooth Quick Release Locking Flex Slim Head Ratchet 12" - Gearwrench

Count on GEARWRENCH to get the job done. Get the 81030 1/4" Drive 72-Tooth Quick Release Locking Flex Slim Head Ratchet 12" here.

www.gearwrench.com