I had the rear actuator clicking problem. I replaced both the air blend and floor/ceiling actuators. I thought the problem was fixed, but a few days later the problem returned. I figured the door must be stuck causing the gears to strip. I finally got around to opening the rear panel back up. I opened the actuator to find that the gears are all intact.

While the actuator was open and plugged in, I started the vehicle. With the AC off, when I start the car the actuator is attempting to move past the end...causing the gears to skip and jump (click). It is happening in both actutors when I turn on the car for about 4-5 times before it stops.

Once it stopped I started playing with the AC controls. It seems that adjusting the temp slightly does not move the actuator. Once I go all the way hot it moves. If I adjust the temp slightly and go back to full hot...it again moves in the same direction. It keeps going in this direction if I keep doing this causing the clicking.

If I go all the way cold, it then switches directions and does the same thing (clicking).

So from what I can gather from my limited testing is that something is wrong with the controls.

Has anyone else had this problem? Is the controls in the circuit board of the actuator? I don't think it is a bad at the control panel since it does the same thing with the front controls or the rear controls and also does this when the car is started with the AC completely off.

Thanks

 

That is odd. Could it be that the new actuator needs to be in a certain position when installed?

 

I think this is just another case of the dorman actuators being a piece of crap. I bought a motocraft one and plugged it in. I ran a test of adjusting the rear temp while watching the actuator and it functions as expected.

Here I was trying to save a few bucks, but now I have to fork out an extra $100 ($50 per actuator) to get it working again. :-(

 

I hate Dorman.

Glad you got it working.