I'm hearing what sounds like a door flapping coming from the very center of my dashboard. The outside temp was 68 and the internal temp was set to 68. I did not have the AC running and had it on face/floor blend with the fan on the lowest setting. My wife was driving and what seemed to be random times there was a flapping sound coming from the dash. It sounded like a plastic flap or door was bouncing or flapping like a screen door flapping open and closed on a windy day. I switched the vent to just face and it continued. I then switched the air completely off and the flapping still continued. This just started happening and I'm not sure what it could be. Does anyone have any suggestions? I would like an idea before I take it in to the dealer because since it does not happen on cue, it is more difficult to reproduce, diagnose and repair.

Thanks!

2012 Expedition Limited, 4wd.

 

It sounds like the blend door is broken. Does it happen when you turn on/off the recirculation button?

 

If its like whats in my Explorer the recirc door and blend door are different doors.

The blend door blends hot and cold air
The recirc door opens and closes outside air

Ive had the recirc door replaced under warranty in my 04 explorer, a $49 part, and $700 labor! Its broken again, but not under warranty so I just removed the door.

 

cstanley is right. The recirc door lets air in from the outside. See if operating this makes the noise go away.

 

Well, it's broken again. Maybe this time they won't scratch the dash up when they replace it. Any idea how to keep this thing from breaking? Leave system on or turn it off? Has anyone else had this problem on the newer model Expeditions? I've seen posts on models which are five years old but nothing on the new models?

 

cheese4420,

This has just started occurring in my 2009 Expedition. It seems to happen when temp is turned down to 60. Where you able to get yours fixed?

Thanks,
Craig

 

I've gotten mine done at the dealership as it was covered under the warranty. After really pressing my service manager, he said the only recommendation he had was to keep it out of the sun when parked. He said the extra heat causes the grease to rout of the gears and they strip out. I just moved from Phoenix to Chicago and when switching from AC to heat in the rear, the rear controller went out. What top notch engineering is all I can say about all of it.

 

Yep, I had to replace the rear controller in our '05. You would think they could fix the issue by now.