My wifes 2003 Explorer has been making a couple strange but different sounds. The first one sounds like as a kid when you used to put a card in your bicycle spokes, but this noise doesn't start right away...it usually takes a minute or two for it to start. The second noise is a clunking noise when you turn the heat off to try and stop the first noise. The second noise sounds vacuum related to me???
Edit: I forgot to mention the first noise is when you turn the heat on, so I'm assuming it is blower motor related because the speed of the noise changes as you select a faster blower speed.

 

sounds like you have it narrowed down to the blower fan. either a bearing is bad on the fan, there is a mouse nest in the duct, or a damper door broke and is touching the fan or----.

 

The first noise sounds like debris in the blower motor. I'm not sure about the 2003, but on earlier models you could remove the blower motor from the engine compartment in about 15 mintues, clear the debris, and reinstall. Simple repair.

 

I would think if it was debris it would start making the noise right away. That isn't the case, it doesn't do it all the time. I'm guessing Steve is right, it's most likely the bigger PITA to fix a broken damper door. Time to do some research.

 

Does the ticking come from the vent to the right of your gas pedal?

I own a 2004 that was doing that exact same thing and the heat finally went. It still ticks but only blows cold air. I took it in and I now need the whole assembly that includes the heater box, evaporator case and trap door motor. THe cost of the part is $500 and the cost for labor on just removing the dash is $250 and that is discounted because my bodyshop does business with them.
It happened because the backing of a airfreshner got caught in the trap door.
I will let you know if I find out anything else. Right now I am hunting the junk yards.

 

I found these directions from another thread for the same problem. I sure hope this is what our problem is. Alot easier to fix and alot cheaper.

#1 pulled trim piece around radio and heater/Ac control ( unplugged heater/ac control)
#2 pulled center console out ( dont forget to remove to screws from back corner of console, you will have to pop off the corner plastic pieces to see these screws)
#3 removed the bottom part of dash under steering wheel ( 2 screws)
#4 removed metal dash support ( piece that goes from floor to dash behind the consloe, two nuts from floor and two bolts from dash)
#5 pulled the floor vent duck work from driving side ( 2 screws )
#6 removed several screws form dash in middle so it would move a little ( you may not have to do this but I did just trying to make it easier to get to the actuator)
#7 pulled the actuator ( 3 screws) and unplugged)
the top screw on top back corner is rough to get to .

you will need a 1/4 inch ratchet with a 7 and 8 MM socket, I also used a three inch extension on some of the screws.
you will also have to have a 8mm wrench to remove the actuator.


I replaced my actuator, it was not turning at all,appeared that the gear inside was gone.
You do not have to get this from the dealer. Advanced Auto ordered one for me. I had it the next day.I paid 49.88. I also found that a Hanyes manual was helpful also ( 18.00)Make sure you get the manual for the correct year you have. I was told that the 2002 and 2003 where the same. The manual I bought was for both years.The wording was not helpful ( as far as locating the front actuator but looking at the pictures helped alot.

I worked on and off on this a couple of days ( took some things apart that was not needed, I was trying to use the steps someone had told me about for a late 90's model, they are notset up the same way.
Once I figured out what had to be done I figure I had a couple of hours in on this.
You could make it easier to get to the actuator if you pullled the complete heater box off but this requires more things to take off ( to do this you would have to unhook and pull the heater core out0

 

I wish I could know for sure that it is the actuator that is starting to go bad on the wifes Exp. I just don't drive it enough to get a solid idea as to the frequency of the issue.
On a side note: Is the actuator the same as the blend door fix that is in the sticky's?

 

Wresleu, we are having the same issue with our 03. Please post anything you find out.

Jessi, thanks, good info.

 

Planning on taking it in to the dealership Friday. HOPEFULLY it will decide to make the noise and act up while I'm there. My luck will be....it won't and they'll think I'm pulling there leg yet again.
I'll let you know my findings.

 

Just got back from the dealer this morning. It cost me $49 for them to diagnose and tell me what I already knew. It's the actuator. They wanted to charge $700 to replace it!!!!!! I basically told them no way in hell would I ever pay that for a $50 part. So time to start pulling the dash.

 

My tech (I work for a bodyshop) replaced the actuator for me yesterday. It took him about 3 hours but he also need a tool that is not listed above to pull out the radio.
I do not have to pay list price and I got the actuator for $37.50. Just putting that out there in case you can wheel & deal. Just be warned that he still scraped his handup in those tight spots.
I now have heat

 

Me too I guess, hopefully the info above from Jessi will help.

I have a extracare ESP but I dont think it is covered (naturally), but Im going to work them over good and see where it gets me.

I am really bitter about this.

 

I'm having the same problem Does anyone have the part number for a new actuator and where I can get my hands on one? Would a store like Advanced Auto parts be able to get me one? Is this a fairly common problem or am I one of the "lucky" ones. I have fairly low miles on it too. Please help as I am not auto savvy.

 

golfdrinker, part#604202 from Advanced Auto at $50.00. Usually a 2 day order time.

 

I had the same problem but in my Auxilary Heater in my 03 Exped. The plenum door won't close all the way to redirect the air to the ceiling. It sounds like a kid is kicking a door panel over and over. Just hit the switch up front to see if this provokes it.
I found this out after the dealer charged me $33 to tell me the problem and that it would be $200 to fix it.
Save your money. It is easy to replace and you can order it online or from Autozone etc. About $50 and easy to change - just have to take things apart to get to it.
I'm sure you guys are talking about the same thing but in the front. Good luck, hope this saves someone time, money, and the annoyance.
Part #604202 Aux. unit blend door actuator
Also found on many fords like rangers etc and many years.