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Originally Posted by bdbertrand The rear a/c on my 03 Expedition makes a noise that changes with the temperature control. it makes a clicking sound when on cold and as you turn it warmer, it makes a thumping sound. i removed the panel, opened up the vent/fan "area" and can see a damper that goes down (when cold) and makes a clicking sound because the motor is continuously pulling it down. as the temperature is changed to warmer, it makes the thumping noise.
The damper moves if i pull on it. Does anyone have any idea what the problem could be? i'm thinking some kind of sensor or relay that would make the motor stop when the damper gets to the desired position.
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saw this post elsewhere...I'm guessing it's your issue
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You'll need part number #YL5Z-19E616-AA costs $86.06 + tax.
The box snaps apart by 2 plastic molded clips on each of the 4 sides.
The gears had teeth that were indeed broken. I did some more investigation as to why this happened. The box is a simple DC motor / gear assembly with a wiper resistance pot to feed back position. The cars controller does not have the correct set points for the stopping points. This problem drives the motor even when the mechanical stop (flap is fully open or closed) is reached. This continued pressure strips the gears and causes the clacking noise.
We all need for FORD to better engineer their vehicles so this does not happen.
I have not dug into the controller to see if the end points can be adjusted to turn off the motor at the end points.
Let us all know if someone does this work.
Hope this helps (it is not cheep)
you can refer to this thread for more info:
http://townhall-talk.edmunds.com/direct/view/.f0a623b
