We have a 2004 Excursion limited edition with 6.0 diesel. This is a recent purchase for our family. This is our first ever Ford and our first ever Diesel.

Now that we are transitioning into colder weather, we recently tried to place the air from AC to Heater. When we tried, we noticed a clicking or hitting noise from the passenger side behind the glove box. When we stopped the air, the noise stopped. When we kept it on the AC, it stopped. Last night we tried to replicate the issue to get more info and we saw that now its stuck on heater and we lost the AC cold air. The module that is making noise is behind the glove box. It is not coming from the actuator that moves air from the feet to the vents, but it is to the right of the actuator and has a plug with about 4 cables plugged into it.

Questions:
What is this module so that I can order a new one?

Does this sound like a bad HVAC blend door actuator? (not trying to steer it that way if its not.)

Any videos on how to replace it? I only see one bolt that mounts it and it appears to be about 8 mm. Is that the only thing holding it?

Thx all

 

So I did some more digging. The sound is coming from the blend door actuator motor

The image and part can be seen here:
Ford F250 Replace Blend Door How to - Ford-Trucks

Step 2 has yellow arrows pointing to the part.

Question, how do I know if its the motor or the actual blend door? Do I have to cut into the plenum box?
Thx

 

99% of the time it is the actuator. They have very small plastic teeth on the gears inside, and the clicking is the teeth slipping. If you remove the actuator, you should be able to turn the door by hand. It should have a little resistance since there is a flap attached to it, and chances are if you hook up power to the actuator one you pull it it will appear to be good. If you want difinitive proof, open up the case of the actuator and inspect the gears.