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I also have the same type of noise, however It sounds like it comes from the passenger side area under the engine compartment. I had ball joints done a couple of months ago and was thinking maybe the caliper or caliper slide pins where sticking or something. It is very loud and jolts the floor board and sterring wheel. I'm going to leave my compressor off and see if it still does it from time to time.
It's the compressor. Had it on my Expy 5.4... haven't heard it yet on the X... won't be surprised if I do. I would believe that it was the blend door, only if it were big enough to walk through and was made of 1/2 inch plate steel!!!
Deffinatly sounds like two seperate problems going on here. I have had other cars that did a pop/thump sound for the blend door but the excursion is quiet as a church mouse as far as the heat/AC and vents for now thankfully.
Do you guys run the A/C compressor all the time? I regularly turn mine off in the winter when running the heat. Just unnescessary wear and tear on a system that is not usually cheap to fix. You DO have to run it a lil about once a month to get the oil circulating to all the o-rings though. A minute or so is plenty of time to handle this task though. You will also get slightly better gas mileage without the compressor cycling all the time. If you dont need the air dried (defroster) or cooled, why run the A/C compressor? This would probably by teh compressors and A/C system a couple years of extra service life before needing repairs if done regularly. Not to mention saving a bit of gas.
I've heard a similar sound on trucks where the leaf springs bind slightly due to either freezing weather or some corrosion between the pressure points of the spring leaves. They'll stick together while the vehicle is sitting unloaded and then when you get into the vehicle and begin to move it, the binding points let go and the springs suddenly equalize.
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