2004 Ford Expedition XLT (rear) AC clicking sound

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charlesjr

United States

#1 Apr 25, 2009
rear ac makes a clicking sound when the temp. knob (both,overhead knob or back seat knob) is turned full cold. if the knobs are turned back 1/8th to 1/4 turn the sound stops. ac and heat still comes out fine just makes the clicking sound.
tijeras_dave

Las Cruces, NM

#2 May 6, 2009
check the small motor assembly that opens the vent in the back. when broken it spins perpetually causing a click click click click. its located in the rear cargo passenger side. its an easy repair by replacment with a wrench and screwdriver
Ron

Austin, TX

#3 Jul 15, 2009
I have the same noise but it is coming from the passenger kick panel. What could it be?
JIMMY

Henderson, NV

#4 Sep 3, 2009
I have the same problem charlesjr..you describe exactly what I have...Does anyone know what the problem might be ?
Jose

Homestead, FL

#5 Sep 4, 2009
The problem you are encountering is a faulty A/C actuator. When you open the rear tail gate, on the right side plastic molding there is an access compartment you can get to by popping the top lid (long, looks like a tray). Inside you will have access to therear A/C unit. There are 2 white electrical cases. One you can easily see and access, and the other on the left hand side of the A/C unit. First check the easy access case by unplugging the electric casing. Turn the AC back on. If no more noise, then this is the faulty actuator. It comes of with three screws and you can purchase at a local auto part store. This actuator is the one that allows you to switch from hot to cold settings. If you unplug this one and the noise persists, you have a bigger problem. The faulty actuator on the left hand side of the AC unit is much harder to replace. You will need to remove the rear paneling to access (unless you have really, really small hands). This actuator is the one that controls the top vents versus the floor vents for the rear AC.
Scott

Coachella, CA

#6 Mar 22, 2010
I had the same problem. I found a similar actuator at the junk yard and used it for parts. All the gears inside my old actuator had teeth missing. So I replaced the gear with the new ones. Here's the kicker...I noticed that no matter which position I have the selector on (ceiling or floor vents), the motor in the actuator is always turning. So there is constant pressure exherted against the gears. This seems odd. But when I re-assembled the actuator and put it all together, everything works great. However, I'm thinking it's only a matter of time until that continuous pressure on the gear teeth is going to cause one/some to break off. Considering how many people have had this problem, maybe it's a design flaw...where the motor never actually cuts-out, and this is causing the problems. Or does my system have another problem somewhere else? NOTE: The only way (I know) to tell if your actuator is doing the same thing as mine is to take it apart and plug it in with the top off. This allows the motor and gears to "pop" (not click or grind) letting you know if the motor is constantly engaged.
Judy TX

Katy, TX

#7 Mar 29, 2010
Same here! I was told it is my actuator, not sure is spelling is correct. It would be $579.00 to fix at the dealership. I brought it in today and my warranty expired on 3/26.10, I have felt sick all day long. Good luck!
Dave PA

Nuremberg, PA

#8 Apr 12, 2011
After reading Scott from Orange CA comments I have to agree that the motor in the actuator runs continually. . Being from Pa there was no need to have the AC on since Sept. and yet the clicking just started on Saturday.The rear temp. setting was set all the way to cool unknown to me. Will start taking things apart this weekend and will update what i find
CAROL

United States

#9 Jun 29, 2011
03 FORD EXPEDITION blows the AC air by the defrost section in the front out of the dash board. minimum cold air is blowing out of the front or the foot area even if i put it to the high. I was told I need a climate control panel that controls the entire AC. $600.00
Jim

San Jose, CA

#10 Sep 19, 2011
Folks, Thanks for the info. As for vent-control problems with the FRONT HVAC system, rarely is the problem going to be an expensive climate control module, as the dealer often tells you it is. Instead, you need to check for problems with the 1/4" rubber vacuum tubing under the hood near the battery. This vacuum tubing supplies the vacuum actuation of the the vent dampers to the FRONT HVAC system. In my case, mild corrosion fluid from the battery dripped onto this tubing causing the problem. It's a simple fix by replacing the affected rubber tubing.
Pete

Duluth, GA

#11 Sep 21, 2011
2006 Expedition - Ford dealer looked at the truck for 10 minutes before coming back with a $600 estimate. I was able to unplug that actuator and it corrected the problem (the one that is easy to get to). Does anyone have a part number or a suggestion on how I can get this replaced?
Sloane

Dallas, TX

#12 Nov 8, 2011
I have had my rear actuator replaced 3 TIMES and it is making the noise AGAIN! The last time I had it done it was less then 6 months ago. We have been taking it to a local guy to fix, but he is still charging us $387 to replace each time. Does anyone know why this continues to happen? Does anyone know how much the actual part is, and where to pick one up? I would like to try and do it myself since they don't seem capable of doing it. Thanks in advanced!
Luke

Austin, TX

#13 Nov 18, 2011
Jose wrote:
The problem you are encountering is a faulty A/C actuator. When you open the rear tail gate, on the right side plastic molding there is an access compartment you can get to by popping the top lid (long, looks like a tray). Inside you will have access to therear A/C unit. There are 2 white electrical cases. One you can easily see and access, and the other on the left hand side of the A/C unit. First check the easy access case by unplugging the electric casing. Turn the AC back on. If no more noise, then this is the faulty actuator. It comes of with three screws and you can purchase at a local auto part store. This actuator is the one that allows you to switch from hot to cold settings. If you unplug this one and the noise persists, you have a bigger problem. The faulty actuator on the left hand side of the AC unit is much harder to replace. You will need to remove the rear paneling to access (unless you have really, really small hands). This actuator is the one that controls the top vents versus the floor vents for the rear AC.
Jose, very well stated. I just followed your instructions and replaced
my rear actuator in my 04 Expedition. I paid $57 for the new one. Sadly,
after inspecting the internals, I see a plastic gear has lost some teeth,
which causes the click. This gear is marked with a 7, with the larger
one marked with a 5. An internal picture (of something similar) is here:

http://i182.photobucket.com/albums/x207/joey_...

Also, one important tip from:

http://redhouseon7th.com/redhouse/howto/2003F...

One last thing...

Before you begin. Turn your HVAC control to either full cold or full hot. Remember which. You'll need to set the position of the new actuator before you insert it. You can't move the actuator manually.

--

I simply plugged in the new actuator prior to installing it, and then
turned on the rear climate control. It moved the actuator in place for
easy installation.

Ultimately, looking at the internals of it, I'd rather repair than replace. Compared with the electronics of the thing, we're probably
looking at a 5 cent part.

If anyone can post a link to actuator gears, you'd save every Ford owner
who is willing to work on a car fifty bucks.
Sloane

Dallas, TX

#14 Nov 18, 2011
Thanks! I'm going to give it a try on my own. I'm sure the fact that I'm a woman they think I want ever look into doing it myself!!
EUGENE -ALABAMA

Daphne, AL

#15 Mar 6, 2012
I HAVE A INTERMITTEN CLICKING IN MY REAR PASSENGER SIDE --I TOOK THE POP OUT PANEL[APPOX. 4"X16x ] ON [ LOOKS LIKE WHEEL COVERING]COMPARTMENT TOOK MY HAND AD\ND HIT IT AND IT HAS QUIT THIS WAS APPROX A WEEK AGE ---- ANYONE KNOW WHATS GOING

THANKS
Scott

Banning, CA

#16 Mar 6, 2012
Not to be rude at all, but you need to read this whole thread. It's been discussed in detail. Good luck!
HBSurferMan85

Wilmington, NC

#17 May 3, 2012
So I bought my 05 expedition in Jan of this year and had it for a few months and then had the first actuator go out.( I assume it was the factory one cause it was white) replaced it out with a new doorman and three weeks later its clicking again. Through warranty switched that motor out thinking it must have been a bad accuator and put the new one in (2nd brand new one from autoo store) here i am again three weeks later and this one is clicking again. Now I dont mind switching them out every three weeks at Doormans expensive (lifetime warranty) but I am tired of having to spend the time doing it. Anyone having the same issues with it constantly going out and is their a permenant fix besides replacing motors every three weeks?
Snowe

Angier, NC

#18 May 8, 2012
My 2003 Ford Expedition is making an annoying noise from the right rear of the vehicle. I replaced the rear blend door actuator which fixed the problem temporarily but 4 days later I am having the same problem. Could anyone help me? What causes the A/C actuator to keep going bad?
kate -NOT a mechanic

Basking Ridge, NJ

#19 May 8, 2012
Just replaced knocking rear ac accuator on 2004 expedition xlt. Man part # was 19E616.$44 at auto parts store. Popped off tray on back panel top, unscrewed 3 srews, pulled a cable.
Did pull cable to test prior to repairing and the knocking had stopped.
Opened it up and plastic gear had broken (little motor was doing fine).
troy

Fort Worth, TX

#20 Jul 7, 2012
just changed the rear temperature actuator (the one on the side) and still no air flow coming through vents or anything. Did some trouble shooting to find out where the clicking noise was coming from and it turned out to be the one on the side. Well, i am still not getting the result I was looking for. Does anyone know what step I need to take next. I even open up the csing to see if everything was working and it was. Do not understand why I am not getting any air through top vents. I even checked the actuator (on top) to see if it was operating efficiently and it checked out okay. Please advise.

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