Popping Noise From Rear A/C Blower '03 Expo

[michaelinchains]

just discovered this popping sound on my `04,will be fixing it as soon as the weather breaks..good looking out

 

[jannypan]

I almost never run the rear AC since I usually roll with the windows down, and usually never have passengers. If the top front controller is left on "Rear", there is a clicking noise every second(kinnda like a grandfather clock). The noise is there regardless of the fan speed chosen in the second row climate control.

 

[Eric]

On my last road trip my rear air started doing the same thing, I have an extended warranty but it's a $100 deductible. After reading this thread it still looks like it's worth paying the $100 to get it done though. I'm amazed at how many people have this problem and Ford just keeps using the same gear on every model year.

 

[DrMark]

Same Problem on my 2003

I read every entry I can find thru this forum. After pullling the side panel off, I found it was in fact broken teeth on the gears as found by many others. As I have no junkyards within fifty miles of me. If anyone has 2 sets they are willing to sell, please PM me. Thanks, DrMark

 

[svtfiveoh]

I have a few sets of gears. I just fixed mine a few months ago.. Anything of trade ?

 

[ELVATO]

If you are pulling them from a junkyard, try to get them from the 1st gen Expeditions. They don't seem to have the same problems with the AC.

 

[jannypana]

I almost never run the rear AC since I usually roll with the windows down, and usually never have passengers. If the top front controller is left on "Rear", there is a clicking noise every second(kinnda like a grandfather clock).

 

[jacket250]

This is a GREAT thread, it's the exact issue I have with my (new to me) I'm confused about what p/n I'm supposed to get from RockAuto though. And should I replace both motors with the assumption that the gear will likely give out soon on the other?










Diablo 3 Items

 

[ELVATO]

From Rockauto, you could try the "DORMAN Part # 604202".

 

[jjkblay]

The problem you have is the door motor has stripped its gear. You can get a new motor at dealer or possibly online for about 29.00. The whole passenger side rear panel needs removed or at least moved out of way and you might look for a mechanically inclined little boy who can get his hands in the small area opened up when you remove the cup holder . It only has two screws and its a bigger pain to remove seat belt bolts and get the panel to move without breaking the snap clips. If you dont want to worry about it you can remove the electrical connector and the door will stay stuck in one position. Otherwise the clicking will continue as long as rear air is turned on.

 

[smo0othride]

The problem you have is the door motor has stripped its gear. You can get a new motor at dealer or possibly online for about 29.00. The whole passenger side rear panel needs removed or at least moved out of way and you might look for a mechanically inclined little boy who can get his hands in the small area opened up when you remove the cup holder . It only has two screws and its a bigger pain to remove seat belt bolts and get the panel to move without breaking the snap clips. If you dont want to worry about it you can remove the electrical connector and the door will stay stuck in one position. Otherwise the clicking will continue as long as rear air is turned on.

It sounds complicated but if you follow the guide, that I believe Elvato posted, it is actually really easy. I had my whole back panel taken apart and put together within about a hour. Just make sure you have all the tools you need before you start, which are listed in the guide.

 

[rctbag]

I give up, looks like I'll be taking to dealership

I've read the threads, and they have been very helpful. But I still can't figure out why i don't have any cold A/C. I checked the freon, it's full. I stopped the popping noise by turning the acuater to where it blows air from the ceiling. It will not get cold at all. I'm lost. No A/C. Anymore suggestions before I hand the dealership about 8 bills?

 

[smo0othride]

I've read the threads, and they have been very helpful. But I still can't figure out why i don't have any cold A/C. I checked the freon, it's full. I stopped the popping noise by turning the acuater to where it blows air from the ceiling. It will not get cold at all. I'm lost. No A/C. Anymore suggestions before I hand the dealership about 8 bills?

Does the A/C work in front? If not then I'm betting your dehydrator valve went bad, let water into the compressor and rusted out the compressor. I also spent 8 bills at the dealership getting a new compressor when that happened to me and at the same time I spent another 400 getting a regulator fixed... 1200 bucks to fix stuff i didn't even need for the expy to be driveable.

 

[shperkins]

Air won't redirect to ceiling vents

Hello,

I'm a bit late to this forum but I've got this problem. We've been through the popping noises before and had the 'rear blend door' replaced about a year ago. The popping returned. Now when the rear A/C is on, the switch between floor and ceiling doesn't light up or switch. Air pours out of the large passenger side vent in the rear panel. Oddly, it seems to be a mixture of warm and cold air. I can feel both.

We are taking a road trip to Florida in two weeks. How do I permanently set the blend door to redirect to the ceiling without having to fix the motors. Is this possible? I'm looking for a quick and easy fix until I can spend more time fixing it for good. Thanks all!

 

[ELVATO]

See posts 38 and 39 on how to get it out. If you can, try to go to a junk yard and get the gears from the older generation Expeditions. They didn't seem to have the same problem. I mean, you're going to have the case open anyways, right

Either way, if you just want to lock it in one setting, take the white box out. Position the vent door so it will blow air through the ceiling vents (I think it's in the closed position). Open the actuator box per the instructions in the posts. Take the gears out, and position the output shaft so as to match the vent door's position (I hope that makes sense).

Put the gears back in, put the cover back on, but don't snap it all back on. Line up the actuator as if it were bolted in. Do a quick test, with the key in the ON position and the rear AC on. Have someone else do this while you hold the actuator in place. Adjust the output shaft as need (why you don't snap the cover right away).

Once you have it all done, bolt everything up, and leave the electrical connector disconnected. Since the motor output has a worm gear, the output shaft of the actuator won't move position.

The reason why I said to try to get gears was since you're already taking the box apart, you might as well swap the gears and be done with it

Either way, it should take maybe 15-30 minutes to do. It helps if you have smaller hands. Also, do as someone else suggested, and tie the tool to your hand. It really sucks having to reach inside for a dropped tool. Make sure to not drop the bolt either.

 

[ELVATO]

See posts 38 and 39 on how to get it out. If you can, try to go to a junk yard and get the gears from the older generation Expeditions. They didn't seem to have the same problem. I mean, you're going to have the case open anyways, right

Either way, if you just want to lock it in one setting, take the white box out. Position the vent door so it will blow air through the ceiling vents (I think it's in the closed position). Open the actuator box per the instructions in the posts. Take the gears out, and position the output shaft so as to match the vent door's position (I hope that makes sense).

Put the gears back in, put the cover back on, but don't snap it all back on. Line up the actuator as if it were bolted in. Do a quick test, with the key in the ON position and the rear AC on. Have someone else do this while you hold the actuator in place. Adjust the output shaft as need (why you don't snap the cover right away).

Once you have it all done, bolt everything up, and leave the electrical connector disconnected. Since the motor output has a worm gear, the output shaft of the actuator won't move position.

The reason why I said to try to get gears was since you're already taking the box apart, you might as well swap the gears and be done with it

Either way, it should take maybe 15-30 minutes to do. It helps if you have smaller hands. Also, do as someone else suggested, and tie the tool to your hand. It really sucks having to reach inside for a dropped tool. Make sure to not drop the bolt either.

 

[shperkins]

See posts 38 and 39 on how to get it out. If you can, try to go to a junk yard and get the gears from the older generation Expeditions. They didn't seem to have the same problem. I mean, you're going to have the case open anyways, right

Either way, if you just want to lock it in one setting, take the white box out. Position the vent door so it will blow air through the ceiling vents (I think it's in the closed position). Open the actuator box per the instructions in the posts. Take the gears out, and position the output shaft so as to match the vent door's position (I hope that makes sense).

Put the gears back in, put the cover back on, but don't snap it all back on. Line up the actuator as if it were bolted in. Do a quick test, with the key in the ON position and the rear AC on. Have someone else do this while you hold the actuator in place. Adjust the output shaft as need (why you don't snap the cover right away).

Once you have it all done, bolt everything up, and leave the electrical connector disconnected. Since the motor output has a worm gear, the output shaft of the actuator won't move position.

The reason why I said to try to get gears was since you're already taking the box apart, you might as well swap the gears and be done with it

Either way, it should take maybe 15-30 minutes to do. It helps if you have smaller hands. Also, do as someone else suggested, and tie the tool to your hand. It really sucks having to reach inside for a dropped tool. Make sure to not drop the bolt either.

Just to be clear, the door to fixate for routing air to the ceiling vents is controlled by the upper, flat-laying motor right? I took the inserts off last night and checked it all out. I see two motors.

Thanks!

 

[ELVATO]

Yea. If you look through the side vent where the air comes out with a flash light, you'll see the door that's controlled by that motor. As it "pops", you'll see how it moves into place, then jumps back.

Either way, you're in luck. The other one (temp control) is a bit harder to replace, necessitating you to take off the whole panel (unless you have very skinny hands, and don't drop anything ).

 

[shperkins]

Update

Yea. If you look through the side vent where the air comes out with a flash light, you'll see the door that's controlled by that motor. As it "pops", you'll see how it moves into place, then jumps back.

Either way, you're in luck. The other one (temp control) is a bit harder to replace, necessitating you to take off the whole panel (unless you have very skinny hands, and don't drop anything ).

Now today the air is blowing from the top vents but it never gets cold. My wife reported that the popping came back then ceased, leaving the air blowing from the right place and it was cold right after that but now the air is tepid, neither hot nor cold regardless of the temp setting.

It seems I need to fix the routing door to the upper vents and is there a temperature blend door as well I need to fix to cold? I'll have to go back through the thread I guess. Thanks!

 

[Clinton]

Now today the air is blowing from the top vents but it never gets cold. My wife reported that the popping came back then ceased, leaving the air blowing from the right place and it was cold right after that but now the air is tepid, neither hot nor cold regardless of the temp setting.

It seems I need to fix the routing door to the upper vents and is there a temperature blend door as well I need to fix to cold? I'll have to go back through the thread I guess. Thanks!

I work for a ford dealer and the most common problem with the rear a/c door is there are motors on top and on the side of the rear a/c case and the gears inside the case are striped out u need to find which motor it is and replace it thats what i usually see at the dealership i work good luck hope this helps.